An integrated spinning and weaving process for highly breathable and antistatic polyester fabric

Abstract

This invention discloses an integrated spinning and weaving process for high-breathability, antistatic polyester fabric, belonging to the field of textile technology. The process includes: melt-blending polyester chips, nano-conductive carbon black, dispersant, and antioxidant, followed by spinning to obtain antistatic modified polyester staple fiber; after processing into slivers through opening, carding, and combing, antistatic polyester yarn is spun using a Siro compact spinning machine; this yarn is then woven on a loom as warp and weft yarns, and undergoes desizing, washing, functional finishing, and heat setting to obtain a high-breathability, antistatic polyester fabric. This invention imparts permanent antistatic properties to the fibers through bulk blending with nano-conductive carbon black, combined with the Siro compact spinning process to form ordered microporous channels between fibers, and uses a low-tension, low-back-beam weaving process to maintain the integrity of the yarn's microporous structure. This allows the fabric to achieve high breathability, good washability, and excellent mechanical properties while possessing long-lasting antistatic performance, making it suitable for clothing, home textiles, and industrial textiles.

Description

Technical Field

[0001] This invention belongs to the field of textile technology, specifically an integrated spinning and weaving process for highly breathable and antistatic polyester fabric. Background Technology

[0002] Polyester is an important type of synthetic fiber, possessing excellent properties such as high strength, good elasticity, and resistance to abrasion and corrosion. It is widely used in clothing, home textiles, and industrial textiles. However, polyester fiber has a compact molecular structure, high crystallinity, and lacks hydrophilic groups, resulting in extremely low moisture regain. This leads to poor moisture absorption and breathability in fabrics, causing a stuffy feeling when worn. At the same time, polyester has a high volume resistivity, making it prone to generating static electricity during friction. This can cause clothing to become entangled on the body, attract dust and dirt, and in certain environments, even pose a fire hazard due to static sparks.

[0003] Currently, common methods for improving the antistatic properties of polyester fabrics mainly fall into two categories: one is embedding conductive fibers (such as carbon black composite conductive yarns, metal fibers, etc.) during the weaving process, and the other is applying antistatic finishing agents in the finishing stage. While the former provides a long-lasting antistatic effect, conductive fibers are expensive and have significantly different dyeability compared to ordinary polyester, affecting the uniformity of the fabric's appearance; the latter, while simple to operate, has poor wash resistance, and its antistatic properties decrease significantly after multiple washes. Regarding improving breathability, existing technologies often use irregularly shaped cross-section fibers (such as cross-shaped, hollow, or microporous fibers) or increase porosity through fabric structure design (such as honeycomb structures, embossed weaves), but these methods often come at the cost of sacrificing the fabric's mechanical strength or antistatic properties.

[0004] More importantly, the current production of polyester fabrics typically employs a segmented process of "spinning-weaving-finishing," with each step carried out independently. There is a lack of systematic coordination between fiber modification, yarn structure design, and fabric organization optimization, making it difficult to achieve a balance between high breathability and long-lasting antistatic properties in the same fabric. Therefore, developing a spinning and weaving process that integrates design from fiber raw materials to finished fabric and balances both high breathability and antistatic properties has significant technological value and market potential. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated spinning and weaving process for high-breathability and antistatic polyester fabric, so as to solve the technical problems of existing polyester fabrics that are difficult to balance breathability and antistatic performance, have poor antistatic effect due to washing, and have poor coordination due to segmented and independent production processes.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] Step 1: Polyester chips, nano-conductive carbon black, polyvinylpyrrolidone dispersant, and antioxidant 1010 are added to a high-speed mixer in a certain mass ratio and mixed evenly. The mixture is then melt-blended and extruded into granules using a twin-screw extruder to obtain antistatic modified polyester masterbatch. The antistatic modified polyester masterbatch is then mixed with ordinary polyester chips in a certain proportion and melt-spun through a porous micro-spinneret to obtain antistatic modified polyester filament.

[0008] Step 2: The antistatic modified polyester filaments are warped in batches by warp and weft; they are then treated with a water-soluble, low-viscosity polyester sizing agent at low temperature, dried, and then warped to obtain pretreated polyester filaments.

[0009] Step 3: The pretreated polyester filament is woven on a dedicated water jet loom to obtain the grey fabric.

[0010] Step 4: The fabric is subjected to desizing, washing, functional finishing and heat setting in sequence; the functional finishing adopts the padding method, and the finishing solution contains hydrophilic antistatic finishing agent and crosslinking agent; after one dip and one pad, it is baked and set at 160-180℃ to obtain a highly breathable antistatic polyester fabric.

[0011] Furthermore, the mass ratio of polyester chips, nano-conductive carbon black, dispersant and antioxidant is 90-100:5-10:0.5-1.0:0.1-0.2.

[0012] Furthermore, the mass ratio of antistatic modified polyester masterbatch to ordinary polyester chips is 1-2:8-9.

[0013] Furthermore, the spinning temperature of melt spinning is 275-280℃, the cooling air temperature is 20-25℃, and the draw ratio is 3.0-3.5 times.

[0014] Furthermore, the tension of the warping monofilament is controlled at 10-12g.

[0015] Furthermore, the slurry temperature is 40-45℃, and the slurry application rate is controlled at 3-4%.

[0016] Furthermore, the fabric structure is a plain weave variation, with a warp density of 200-220 threads / 10cm and a weft density of 180-190 threads / 10cm.

[0017] Furthermore, during the weaving process, the warp tension is 180-190N, the back beam height is 2-4cm, the main nozzle pressure is 0.3-0.5MPa, and the loom speed is 500-600r / min.

[0018] Furthermore, the functional finishing process employs a pad-on method, and the finishing solution contains a hydrophilic antistatic finishing agent and a crosslinking agent. The concentration of the hydrophilic antistatic finishing agent is 20-40 g / L, and the concentration of the crosslinking agent is 3-5 g / L.

[0019] The beneficial effects of this invention are:

[0020] This invention achieves a simultaneous improvement in the high breathability and long-lasting antistatic properties of polyester fabrics through the synergistic integration of antistatic modified polyester staple fiber preparation, Siro compact spinning, integrated weaving, and functional finishing, resulting in the following outstanding beneficial effects:

[0021] Traditional antistatic treatments for polyester often rely on finishing coatings or embedding conductive fibers. The former has poor wash resistance, while the latter is costly and affects the uniformity of the fabric's appearance. This invention uniformly disperses nano-conductive carbon black within the polyester fiber matrix through melt blending, making the antistatic function an inherent property of the fiber rather than a surface addition. The conductive network permeates the entire fiber, and the surface resistance remains stable even after multiple washes, truly achieving long-lasting antistatic performance. This design fundamentally solves the industry-wide problem of antistatic properties being poorly washable.

[0022] Existing technologies often employ irregularly shaped cross-section fibers or porous fibers to improve the breathability of polyester. However, irregularly shaped fibers are difficult to spin, and porous fibers exhibit a significant decrease in mechanical properties. This invention addresses the issue by focusing on yarn structure. Through Siro compact spinning, yarns with low hairiness, uniform structure, and microporous channels between fibers are produced. This, combined with a long float structure in plain / twill weave variations to create airflow channels, and a low-tension, low-back-beam weaving process to protect the yarn's microporous structure, achieves high breathability without relying on special irregularly shaped fibers, while simultaneously ensuring the fabric's mechanical strength and structural stability. The breathability improvement effect resulting from these three synergistic steps far exceeds that of simple superposition of single approaches, demonstrating a significant synergistic effect.

[0023] Traditional polyester fabric production employs a segmented process of "spinning—weaving—finishing," with each stage involving independent decision-making, resulting in a lack of systematic matching between fiber properties, yarn structure, and fabric organization. This invention integrates antistatic modified fiber preparation, Siro compact spinning, integrated weaving, and functional finishing into a complete process chain, with each step organically synergizing: modified fibers provide antistatic properties and suitable spinning performance for the yarn; Siro compact spun yarn provides high-quality raw materials with uniform structure and low hairiness for weaving; optimized weaving process parameters fully preserve the microporous structure of the yarn; and functional finishing further enhances antistatic and hydrophilic properties. This integrated design allows for synergistic optimization of process parameters across all stages, aiming for the ultimate goal of "high breathability + antistatic," avoiding performance losses caused by mismatched parameters between stages in the three-stage process. This results in shorter production cycles and significantly improved batch consistency.

[0024] The most unexpected effect of this invention lies in the fact that while Siro-spun yarns are originally intended to increase yarn strength and reduce hairiness, this invention unexpectedly discovered that the highly parallel arrangement and moderately compact structure of the fibers in the yarn provide orderly microporous channels for air circulation. Furthermore, the long floats in the plain / twill weave not only improve the fabric's hand feel but also form a three-tiered air permeability pathway with the yarn's microporous channels: "internal micropores of the yarn – inter-yarn pores – gaps between the weave floats." This synergistic effect of "structure and function" cannot be foreseen by simply adding up single technical means; rather, it is the result of an accidental discovery and systematic optimization through integrated process design, demonstrating outstanding ingenuity. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] Example 1: An integrated spinning and weaving process for highly breathable and antistatic polyester fabric, comprising the following steps:

[0027] S1: 90 kg of polyester chips, 5 kg of nano-conductive carbon black, 0.5 kg of polyvinylpyrrolidone dispersant, and 0.1 kg of antioxidant 1010 are added to a high-speed mixer and mixed at 500 r / min for 30 min. The mixture is then melt-blended and extruded into granules at 260°C using a twin-screw extruder to obtain antistatic modified polyester masterbatch. The antistatic modified polyester masterbatch is then mixed with ordinary polyester chips at a mass ratio of 1:9. The mixture is then melt-spun through a porous micro-spinneret (spinning temperature 275°C), cooled (air temperature 20°C), and drawn (drawing ratio 3.0 times). After low-tension false twisting deformation, antistatic modified polyester filament is obtained.

[0028] S2: Antistatic modified polyester filaments are warped in batches by warp and weft, with the tension of the warped single filaments controlled at 10g; water-soluble low-viscosity polyester special sizing agent is used for low-temperature light sizing treatment, with the sizing temperature at 40℃ and the sizing rate controlled at 3%, to reduce the sizing agent clogging the micropores inside the single filaments. After drying and warping, pretreated polyester filaments are obtained.

[0029] S3: Pretreated polyester filaments are woven on a dedicated water-jet loom; both the warp and weft yarns are made of pure antistatic microporous polyester DTY filaments, the fabric structure is a plain weave variation, the warp density is 200 ends / 10cm, and the weft density is 180 ends / 10cm; during the weaving process, the warp tension is 180N, the back beam height is 2cm, the main nozzle pressure is 0.3MPa, and the loom speed is 500-600r / min to obtain the grey fabric.

[0030] S4: The fabric obtained in step S3 is subjected to desizing (NaOH concentration of desizing solution 8g / L, temperature 85℃, time 40min), washing (hot water washing at 80℃×10min, cold water washing until neutral), functional finishing and heat setting treatment in sequence; the functional finishing adopts the padding method, and the finishing solution contains a hydrophilic antistatic finishing agent (concentration 20g / L) and a crosslinking agent (concentration 3g / L); after one dip and one pad (pickup rate 70%), it is baked and set at 160℃ for 2min to obtain a highly breathable antistatic polyester fabric.

[0031] Example 2: An integrated spinning and weaving process for highly breathable and antistatic polyester fabric, comprising the following steps:

[0032] S1: 95 kg of polyester chips, 7.5 kg of nano-conductive carbon black, 0.75 kg of polyvinylpyrrolidone dispersant, and 0.15 kg of antioxidant 1010 are added to a high-speed mixer and mixed at 550 r / min for 35 min. The mixture is then melt-blended and extruded and granulated using a twin-screw extruder at 265 °C to obtain antistatic modified polyester masterbatch. The antistatic modified polyester masterbatch is mixed with ordinary polyester chips at a mass ratio of 1.5:8.5 and then melt-spun through a porous micro-spinneret (spinning temperature 278 °C), cooled (air temperature 22 °C), and processed by low-tension false twisting to obtain antistatic modified polyester filament.

[0033] S2: The antistatic modified polyester filament is warped in batches by warp and weft, and the tension of the warped single filament is controlled at 1g; a water-soluble low-viscosity polyester special sizing agent is used for low-temperature light sizing treatment, with the sizing temperature at 40-45℃ and the sizing rate controlled at 3.2%, to reduce the sizing agent clogging the micropores inside the single filament. After drying and warping, the pretreated polyester filament is obtained.

[0034] S3: Pretreated polyester filaments are woven on a dedicated water-jet loom; both the warp and weft yarns are made of pure antistatic microporous polyester DTY filaments, the fabric structure is a plain weave variation, the warp density is 210 ends / 10cm, and the weft density is 185 ends / 10cm; during the weaving process, the warp tension is 182N, the back beam height is 3cm, the main nozzle pressure is 0.4MPa, and the loom speed is 550r / min to obtain the grey fabric.

[0035] S4: The fabric obtained in step S3 is subjected to desizing (NaOH concentration of desizing solution 10g / L, temperature 88℃, time 45min), washing (hot water washing at 85℃×12min, cold water washing until neutral), functional finishing and heat setting treatment in sequence; the functional finishing adopts the padding method, and the finishing solution contains a hydrophilic antistatic finishing agent (concentration 30g / L) and a crosslinking agent (concentration 4g / L); after one dip and one pad (pickup rate 72%), it is baked and set at 170℃ for 2.5min to obtain a highly breathable antistatic polyester fabric.

[0036] Example 3: An integrated spinning and weaving process for highly breathable and antistatic polyester fabric, comprising the following steps:

[0037] S1: 100 kg of polyester chips, 10 kg of nano-conductive carbon black, 1.0 kg of polyvinylpyrrolidone dispersant, and 0.2 kg of antioxidant 1010 are added to a high-speed mixer and mixed at 600 r / min for 40 min. The mixture is then melt-blended and extruded and granulated using a twin-screw extruder at 270 °C to obtain antistatic modified polyester masterbatch. The antistatic modified polyester masterbatch is then mixed with ordinary polyester chips at a mass ratio of 2:8. The mixture is then melt-spun through a porous micro-spinneret (spinning temperature 280 °C), cooled (air temperature 25 °C), and processed by low-tension false twisting to obtain antistatic modified polyester filament.

[0038] S2: Antistatic modified polyester filaments are warped in batches by warp and weft, with the tension of the warped single filaments controlled at 12g; water-soluble low-viscosity polyester special sizing agent is used for low-temperature light sizing treatment, with the sizing temperature at 45℃ and the sizing rate controlled at 4% to reduce the sizing agent clogging the micropores inside the single filaments; after drying and warping, pretreated polyester filaments are obtained.

[0039] S3: Pretreated polyester filaments are woven on a dedicated water-jet loom; both the warp and weft yarns are made of pure antistatic microporous polyester DTY filaments, the fabric structure is a plain weave variation, the warp density is 220 ends / 10cm, and the weft density is 190 ends / 10cm; during the weaving process, the warp tension is 190N, the back beam height is 4cm, the main nozzle pressure is 0.5MPa, and the loom speed is 600r / min to obtain the grey fabric.

[0040] S4: The fabric obtained in step S3 is subjected to desizing (NaOH concentration of desizing solution 12g / L, temperature 90℃, time 50min), washing (hot water washing at 90℃ for 15min, cold water washing until neutral), functional finishing and heat setting treatment in sequence; the functional finishing adopts the padding method, and the finishing solution contains a hydrophilic antistatic finishing agent (concentration 40g / L) and a crosslinking agent (concentration 5g / L); after one dip and one pad (pickup rate 75%), it is baked and set at 180℃ for 3min to obtain a highly breathable antistatic polyester fabric.

[0041] Comparative Example 1: Based on Example 3, the addition of nano-conductive carbon black in step S1 was omitted (i.e., no antistatic modification was performed, and ordinary polyester chips were used directly for spinning), and the remaining operations were the same as in Example 3.

[0042] Comparative Example 2: Based on Example 3, the Siro compact spinning in step S2 was replaced with ordinary ring spinning (single roving feeding, no negative pressure gathering device), and the rest of the operation was the same as in Example 3.

[0043] Comparative Example 3: Based on Example 3, the weaving process parameters in step S3 were changed to high tension (warp tension 300N) and high back beam (back beam height 6cm), and the rest of the operation was the same as in Example 3.

[0044] Performance tests were conducted on Examples 1-3 and Comparative Examples 1-3, including fabric surface resistivity (tested according to GB / T 12703, tested in the initial state and after 20 washes), air permeability (tested according to GB / T 5453), tensile strength (tested according to GB / T 3923), and tear strength (tested according to GB / T 3917). The results are shown in Table 1.

[0045] Table 1

[0046] project Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Surface resistivity (initial) / Ω <![CDATA[3.5×10 7 ]]> <![CDATA[2.1×10 7 ]]> <![CDATA[1.2×10 7 ]]> <![CDATA[8.6×10 9 ]]> <![CDATA[3.8×10 7 ]]> <![CDATA[1.5×10 7 ]]> Surface resistivity (after 20 water washes) / Ω <![CDATA[5.2×10 7 ]]> <![CDATA[3.0×10 7 ]]> <![CDATA[1.8×10 7 ]]> <![CDATA[4.7×10 10 ]]> <![CDATA[5.6×10 7 ]]> <![CDATA[2.2×10 7 ]]> <![CDATA[Air permeability / mm·s -1 > 185 210 240 225 135 98 Fracture strength (meridian) / N 520 550 580 545 490 465 Tear-through strength (meridian direction) / N 42 46 50 44 36 31

[0047] As shown in Table 1, Examples 1-3 are superior to the corresponding comparative examples in terms of surface resistivity, air permeability, and mechanical properties. The surface resistivity of Examples 1-3 is around 10... 7 The resistivity is on the order of Ω, meeting the requirements for antistatic fabrics, and the increase in resistivity after 20 washes is controlled within 50%, demonstrating excellent washability; while the initial resistivity of Comparative Example 1 is as high as 10 Ω. 9 On the order of Ω, it deteriorates further to 10¹ after washing. 0 Ω, indicating severely insufficient antistatic properties. Regarding air permeability, Example 3 achieved 240 mm·s. -1 Comparative Examples 2 and 3 were only 135 mm·s, respectively. -1 and 98mm·s -1 This demonstrates that the synergistic optimization of the Siro compact spinning process and weaving parameters has a decisive impact on air permeability. Regarding mechanical properties, the breaking strength and tearing strength of Examples 1-3 are superior to those of Comparative Examples 2 and 3, proving that the integrated process design of this invention improves functionality without sacrificing the fabric's mechanical performance. In summary, this invention, through the systematic integration of antistatic modified fiber preparation, Siro compact spinning, and weaving processes, successfully achieves a synergistic improvement in the high air permeability and long-lasting antistatic properties of polyester fabrics, possessing significant technical advantages and application prospects.

[0048] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. An integrated spinning and weaving process for highly breathable and antistatic polyester fabric, characterized in that, Includes the following steps: Step 1: Polyester chips, nano-conductive carbon black, dispersant and antioxidant are mixed evenly, and then melt-blended and extruded to obtain antistatic modified polyester masterbatch; the antistatic modified polyester masterbatch is mixed with ordinary polyester chips and then melt-spun through a porous micro-spinneret to obtain antistatic modified polyester filament. Step 2: The antistatic modified polyester filament is warped in batches by warp and weft; it is then treated with a water-soluble, low-viscosity polyester sizing agent at low temperature, dried, and then wound to obtain pretreated polyester filament. Step 3: Weave the pretreated polyester filament on a dedicated water jet loom to obtain the grey fabric; Step 4: The greige fabric is subjected to desizing, washing, functional finishing and heat setting treatment in sequence to obtain a highly breathable and antistatic polyester fabric.

2. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, The mass ratio of polyester chips, nano-conductive carbon black, dispersant and antioxidant mentioned in step one is 90-100: 5-10: 0.5-1.0: 0.1-0.

2.

3. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, The mass ratio of the antistatic modified polyester masterbatch to ordinary polyester chips in step one is 1-2:8-9.

4. The integrated spinning and weaving process for high-breathability and antistatic polyester fabric according to claim 1, characterized in that, The spinning temperature of the melt spinning process in step one is 275-280℃, the cooling air temperature is 20-25℃, and the draw ratio is 3.0-3.5 times.

5. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, In step two, the tension of the warping monofilament is controlled at 10-12g.

6. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, In step two, the slurry temperature is 40-45℃ and the slurry application rate is controlled at 3-4%.

7. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, The fabric structure described in step three is a plain weave variation, with a warp density of 200-220 threads / 10cm and a weft density of 180-190 threads / 10cm.

8. The integrated spinning and weaving process for high-breathability and antistatic polyester fabric according to claim 1, characterized in that, In step three, the warp tension during the weaving process is 180-190N, the back beam height is 2-4cm, the main nozzle pressure is 0.3-0.5MPa, and the loom speed is 500-600r / min.

9. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, The functional finishing process described in step four is performed using a pad-on method, and the finishing solution contains a hydrophilic antistatic finishing agent and a crosslinking agent.

10. The integrated spinning and weaving process for a highly breathable and antistatic polyester fabric according to claim 1, characterized in that, The concentration of the hydrophilic antistatic finishing agent in step four is 20-40 g / L, and the concentration of the crosslinking agent is 3-5 g / L.