A fabric with thickened muslin plain and a preparation process thereof

Abstract

This invention relates to the field of textile technology and discloses a fabric with a thickened modal plain weave and its preparation process. The composition and weight parts of the fabric are: 28-32 parts of natural sports wool fiber; 50-56 parts of modal fiber; and 13-19 parts of carbon brushed fiber. By pre-treating the natural sports wool fiber, modal fiber, and carbon brushed fiber, they are spun into three yarns with different structures and functions: A yarn, B yarn, and C yarn. Then, they are spun using a three-channel asymmetric airflow focusing spinning and woven with the single yarn axially oriented. The three fibers are woven in a controlled asymmetric gradient distribution in the radial section of the single yarn with a unified orientation. This makes the inner layer of the fabric mainly modal to achieve softness and skin-friendliness, while the outer layer is enriched with wool, ultimately achieving the beneficial effect of a three-layer integrated gradient functional zoning with micro-fleece and skin-friendly properties.

Description

Technical Field

[0001] This invention relates to the field of textile technology, specifically to a fabric with a thickened modal plain weave and its preparation process. Background Technology

[0002] Modal / wool blends are widely used in the apparel industry due to their combination of the softness and comfort of modal and the warmth and elasticity of wool. In existing technologies, modal / wool blends are typically woven by uniformly blending the two fibers in a certain proportion (e.g., 20-40 wt% wool and 60-80 wt% modal); or they employ a multi-layered composite structure, such as short fiber layers, long fiber layers, and brushed layers, with each layer connected by twisting and plying sections; or they use a core-sheath structure, with silk, long-staple cotton, etc., as the core layer and modal and wool as the outer layers. Regarding brushing finishing, existing technologies often use carbon brushing rods or carbon brushing machines to perform overall brushing treatment on the fabric, such as using carbon brushing rods at a speed of 900 rpm; or using a warp-knitted elastic carbon brushed fabric production method, brushing after washing and pre-setting, followed by finishing and dyeing processes. In terms of antistatic treatment, existing technologies mostly employ methods such as blending conductive fibers with wool fibers, applying antistatic finishing agents, or low-temperature plasma treatment.

[0003] However, the aforementioned existing technologies still have the following shortcomings: First, uniform blending results in a consistent fiber distribution between the inner and outer layers of the fabric, making it impossible to achieve ultimate softness on the skin-contact surface and a differentiated, brushed, skin-friendly feel on the outer layer. While multi-layer composite or core-sheath structures achieve a certain degree of layering, the bonding between these layers requires methods such as twisting, sewing, or gluing, which are complex processes and can easily affect the fabric's skin-friendliness and breathability. Second, existing brushing processes mostly use carbon brushing rods or carbon brushing machines to brush the entire fabric surface. The brushing force is strong and it is difficult to precisely control the processing depth, easily leading to damage to the overall fibers of the fabric, especially the inner modal fibers, which lose their natural softness due to abrasion. Third, to impart antistatic properties to wool fabrics, existing technologies often use a simple mixing of conductive fibers with wool fibers before spinning. The conductive fibers are randomly distributed in the yarn, resulting in unstable antistatic efficiency. Furthermore, antistatic finishing and softening finishing often conflict with each other, making it difficult to achieve both simultaneously.

[0004] Therefore, it is necessary to develop a thickened modal plain weave fabric that combines a soft, skin-friendly feel with a micro-fleece-like texture, while also possessing durable antistatic properties and not damaging the soft nature of the inner fibers, in order to meet consumers' pursuit of a "second skin" wearing experience. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a fabric with a thickened modal plain weave and its manufacturing process. The fabric has the advantages of achieving three-layer gradient functional zoning in one-time fabric forming, combining the outer layer of ultra-fine fleece with the inner layer of softness, with significant differences in hand feel between the front and back sides, durable and stable antistatic performance, and excellent overall wearing comfort. It solves the problems of existing modal / wool blended fabrics where uniform blending leads to similar tactile feel between the inner and outer layers, full-width abrasion damages the inner layer fibers and causes loss of softness, and the difficulty in achieving both antistatic and soft performance.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a fabric with a thickened modal plain weave, wherein the composition and weight parts of the fabric are: 28-32 parts of natural sports wool fiber; 50-56 parts of modal fiber; and 13-19 parts of carbon brushed fiber.

[0007] Preferably, the fineness of the natural sports wool fiber is controlled at 16.5-18.5μm, and the crimp is controlled at 7.5-8.5 curls / cm.

[0008] Preferably, the modal fiber has a fineness of 1.0 to 1.3 dtex, a length of 34 to 38 mm, and a wet strength of ≥4.2 cN / dtex.

[0009] Preferably, the carbon nanofiber loading is controlled at 1.5-1.8 wt%, and the fiber diameter is controlled at 1.8-2.5D.

[0010] A manufacturing process for a fabric with a thickened modal plain weave, comprising the following steps, based on the aforementioned formulation of a fabric with a thickened modal plain weave: Step 1: Ingredient preparation: Use natural sports wool fiber, modal fiber and carbon brushed fiber as raw materials, weigh them according to the formula weight parts and pre-treat them; Step 2, Sectional Single Yarn Spinning: The pretreated natural sports wool fiber, modal fiber and carbon brushed fiber are spun into three different yarns with different structures and functions: A yarn, B yarn and C yarn. Step 3, Gradient Weaving: Using a double-sided multi-layer loom, yarns A, B, and C are woven in a three-layer structure (inner-middle-outer) in one pass to obtain the complete fabric. The total weight of the three layers is controlled between 220 and 280 g / m², with the inner layer accounting for 30% to 35%, the middle layer accounting for 25% to 30%, and the outer layer accounting for 35% to 45%. Step 4, Outer Layer Directional Micro-Fluffing: The outer layer of the fabric is subjected to a three-stage progressive brushing process using ceramic fiber brush rollers. Step 5, Post-processing: First, set the brushed fabric under low temperature relaxation conditions, and then use a non-silicone softener to soften and finish the inner layer of the fabric. Step Six: Finished Product Functional Testing: After the finished fabric has been shaped and placed in a standard environment for equilibration, quality indicators and functional re-testing verification are performed.

[0011] Preferably, the component pretreatment in step one includes: (1) Place natural sports wool fibers in a low-frequency ultrasonic-assisted low-temperature plasma treatment device. The treatment medium is a mixture of argon gas and trace water vapor with a volume ratio of 95:5. The plasma discharge power is controlled at 80-100W, the treatment time is 60-90 seconds, and the temperature inside the device is controlled at 35-36℃. (2) The modal fiber was placed in an ice-water mixing bath. The mixing bath was a mixed solution of deionized water and ε-polylysine with a bath ratio of 1:20 to 1:25. The concentration of ε-polylysine was controlled at 0.3 to 0.4 g / L. The treatment process adopted a programmed temperature control: the initial temperature was 18 to 20°C, the temperature was lowered to 2 to 4°C at a rate of 0.3 to 0.5°C / min, and the temperature was kept for 30 to 45 minutes. Then the temperature was raised to 20 to 22°C at a rate of 1 to 3°C / min, and the temperature was kept for 15 to 18 minutes. The entire treatment process was accompanied by intermittent low-speed stirring at a speed of 30 to 45 r / min and stirring for 1 minute and stopping for 3 minutes. (3) Place the carbon fiber in a supercritical carbon dioxide treatment vessel and treat it for 20 to 30 minutes under supercritical conditions of 12 to 14 MPa and 40 to 45 °C. During the supercritical treatment, apply an alternating electric field with a frequency of 50 to 80 Hz and a field strength of 5 to 8 V / cm. After the treatment, gradually depressurize to atmospheric pressure at a rate of 3 to 5 MPa / min.

[0012] Preferably, in step two, the single yarn is spun in sections: (1) Inner layer skin-friendly yarn: 82% to 88% of modal fiber and 12% to 18% of natural sports wool fiber are mixed and spun with low twist, with twist controlled at 520 to 620 T / m and yarn count of 32 to 38 Nm to obtain inner layer A yarn; (2) Intermediate layer functional yarn: 55% to 65% of natural sports wool fiber and 35% to 45% of carbon brushed fiber are spun using S / Z bidirectional twisting method: first set the twist to 350 to 450 T / m and initially twist in the S direction; then adjust the twist to 250 to 350 T / m and retwist in the Z direction, with the total twist controlled at 600 to 800 T / m and the yarn count 28 to 34 Nm to obtain intermediate layer B yarn; (3) Outer layer fleece yarn: 78% to 85% of natural sports wool fiber and 15% to 22% of modal fiber are mixed and spun with high twist, with twist controlled at 980 to 1020 T / m and yarn count of 30 to 36 Nm to obtain outer layer C yarn.

[0013] Preferably, the gradient weaving process in step three is as follows: S1.1 Inner layer: Made with yarn A as the weft yarn, using a plain weft knit structure, with a loop length of 2.8–3.0 mm; S1.2, Intermediate layer: Using B yarn as the connecting yarn, the inner layer and outer layer are connected by a tuck weave, with a tuck length of 4.8-5.4mm; S1.3 Outer layer: Made of C yarn as warp, with a plain weave structure, warp density of 310-330 threads / 10cm and weft density of 270-290 threads / 10cm.

[0014] Preferably, the outer layer directional microfibrillation process in step four is as follows: S2.1 The first pre-grinding process is carried out under low tension of 10-13 kg, with a brush roller speed of 1000-1200 r / min and a fabric feed speed of 6-8 m / min to build the basic texture. S2.2 After entering the second fine grinding stage, increase the brush roller speed to 1500-1600 r / min and maintain the same fabric feeding speed; S2.3 In the final trimming process, the rotation speed is adjusted back to 900-1000 r / min. Throughout the process, the surface temperature of the roller is kept constant in the range of 40-45℃, ultimately forming a distinct and uniform ultrafine microfiber structure.

[0015] Preferably, the post-processing flow in step five is as follows: S3.1 Low temperature setting: The brushed fabric is relaxed and set at 100-105℃, with overfeed set between 4% and 6%; S3.2 Inner layer softening finishing: Using a spraying method, a non-silicone softener with a mass concentration of 10-12 g / L is sprayed onto the inner layer of the fabric, with the spraying amount set to 20-25 g / m², finally obtaining a fabric with a thickened modal plain weave.

[0016] Compared with the prior art, the present invention provides a fabric with thickened modal plain weave and its preparation process, which has the following beneficial effects: 1. This invention pre-treats natural sports wool fibers, modal fibers, and carbon brushed fibers, and spins them into three yarns with different structures and functions: A yarn, B yarn, and C yarn. Then, through three-channel asymmetric airflow gathering spinning and single yarn axial orientation weaving, the three fibers are artificially controlled asymmetric gradient distribution in the radial section of the single yarn and woven in a unified direction. This achieves the beneficial effect of a three-layer integrated gradient functional zoning, with the inner layer of the fabric mainly composed of modal to achieve softness and skin-friendliness, and the outer layer enriched with wool to achieve micro-fluffy skin-friendly properties.

[0017] 2. This invention uses a selective ceramic brush to perform three progressive low-speed fine grinding processes on the front side, which only directional micro-fleecing treatment on the outer layer of the fabric. This achieves the beneficial effect of finely grinding the outer wool scale layer to form ultra-fine fleece, while the inner modal fiber retains its soft nature completely, and the difference in feel between the front and back sides is significant.

[0018] 3. This invention achieves the beneficial effects of durable and stable antistatic properties of the fabric, intact outer micro-fleece morphology and soft and skin-friendly inner layer, and significantly improved overall wearing comfort by using supercritical carbon dioxide synergistic alternating electric field pretreatment of carbon brushed fibers and their alternating distribution in the yarn, combined with low-temperature relaxation setting and selective softening finishing of the inner layer. Attached Figure Description

[0019] Figure 1 This is a flowchart of the fabric process for the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 A fabric with a thickened modal plain weave, the raw material composition and function of which are shown in the table below: Table 1 Example 1 A manufacturing process for a fabric with a thickened modal plain weave, comprising the following steps, based on the aforementioned formulation of a fabric with a thickened modal plain weave: Step 1: Ingredient preparation: Use natural sports wool fiber, modal fiber and carbon brushed fiber as raw materials, weigh them according to the formula weight parts and pre-treat them; Specifically, the component pretreatment in step one: (1) Place natural sports wool fibers in a low-frequency ultrasonic-assisted low-temperature plasma treatment device. The treatment medium is a mixture of argon gas and trace water vapor with a volume ratio of 95:5. The plasma discharge power is controlled at 100W, the treatment time is 90 seconds, and the temperature inside the device is controlled at 35℃. (2) The modal fiber was placed in a gradient cooling ice-water mixed bath. The mixed bath was a mixed solution of deionized water and ε-polylysine (ε-PL), wherein the concentration of ε-polylysine was controlled at 0.3 g / L. The treatment process adopted a program temperature control: the initial temperature was 18℃, the temperature was reduced to 2℃ at a rate of 0.3℃ / min, and the temperature was kept for 40 minutes. Then the temperature was raised to 20℃ at a rate of 2℃ / min, and the temperature was kept for 16 minutes. The entire treatment process was accompanied by intermittent low-speed stirring at a speed of 35 r / min, stirring for 1 minute and stopping for 3 minutes. (3) Place the carbon fiber in a supercritical carbon dioxide (scCO2) treatment vessel and treat it for 25 minutes under supercritical conditions of 12 MPa and 40 °C. During the supercritical treatment, an alternating electric field with a frequency of 50 Hz and a field strength of 5 V / cm is applied simultaneously. After the treatment, the pressure is gradually reduced to atmospheric pressure at a rate of 3 MPa / min.

[0022] Step 2, Sectional Single Yarn Spinning: The pretreated natural sports wool fiber, modal fiber and carbon brushed fiber are spun into three different yarns with different structures and functions: A yarn, B yarn and C yarn. Specifically, in step two, the single yarn is spun in sections: (1) Inner layer skin-friendly yarn (A yarn): 82% to 88% of modal fiber and 12% to 18% of natural sports wool fiber are mixed and spun with low twist, with the twist controlled at 600T / m and the yarn count at 38Nm to obtain the inner layer A yarn. Due to the low twist, the yarn is fluffy and soft, and there is no pressure when it comes into direct contact with the skin. In addition, the addition of a small amount of wool can utilize its natural crimp elasticity to provide slight support for the inner layer, and ultimately prevent the fabric from becoming too soft and slumped. (2) Intermediate layer functional yarn (B yarn): 55% to 65% of natural sports wool fiber and 35% to 45% of carbon brushed fiber are spun using S / Z bidirectional twisting: first, the twist is set to 400T / m and the initial twist is in the S direction; then the twist is adjusted to 300T / m and the re-twisting is in the Z direction. The total twist is controlled at 700T / m and the yarn count is 32Nm to obtain the intermediate layer B yarn. Due to the S / Z bidirectional twisting, the two fibers are alternately distributed in the yarn cross section. The conductive network of carbon brushed fiber and the elastic crimp of wool fiber interpenetrate each other and finally form a uniform conductive-elastic synergistic network. (3) Outer layer pile yarn (C yarn): 78% to 85% of natural sports wool fiber and 15% to 22% of modal fiber are mixed and spun with high twist, with the twist controlled at 1000T / m and the yarn count at 34Nm to obtain the outer layer C yarn. Due to the high twist, the yarn structure is compact and the surface hair is less, which is conducive to the formation of uniform and fine micro-pile when the ceramic brush is polished, rather than coarse and long messy hair. The addition of a small amount of modal can reduce the rigidity of the yarn, which will make the pile soft and not prickly after polishing.

[0023] Step 3, Gradient Weaving: Using a double-sided multi-layer loom, yarns A, B, and C are woven into a three-layer structure (inner-middle-outer) in one pass to obtain the complete fabric. The total weight of the three layers is controlled at 250 g / m², with the inner layer accounting for 33%, the middle layer for 28%, and the outer layer for 40%. Specifically, the gradient weaving process in step three: S1.1 Inner layer (skin-contact surface): Made with yarn A as the weft yarn, using plain weft knitting, with a loop length of 2.8mm. The surface of the plain weft knitting is smooth, resulting in a low coefficient of friction when in direct contact with the skin. Combined with the low-twist and soft characteristics of yarn A, it achieves a "pressure-free" skin-contact experience. S1.2, Intermediate Layer (Functional Core Layer): Using B yarn as the connecting yarn, the inner and outer layers are linked by a tuck weave. The tuck length is 5.0mm. The loops formed by the tuck weave create micro air chambers between the layers, which not only enhances the warmth but also provides elastic cushioning for the fabric. S1.3 Outer layer (brushed surface): C yarn is used as the warp yarn and plain weave is adopted. The warp density is 320 threads / 10cm and the weft density is 280 threads / 10cm. The plain weave structure is tight and the surface is flat, providing a uniform brushing base for subsequent ceramic brush brushing.

[0024] Step 4, Outer layer directional micro-fleecing: The outer layer of the fabric (C yarn surface) is subjected to three progressive brushing processes using ceramic fiber brush rollers. The progressive logic of the three brushing processes is as follows: the first process uses a low speed to open the surface fibers of the C yarn; the second process uses a high speed to finely polish the wool scale layer, polishing the scale flanges into ultra-fine fleeces; and the third process uses a low speed to adjust the uniformity of the fleece surface. Specifically, the outer layer directional microfibrillation process in step four: S2.1 The first pre-grinding process is carried out under low tension of 12kg, with a brush roller speed of 1100r / min and a fabric feed speed of 7m / min to build the basic texture. At this time, the low tension environment can effectively prevent excessive fiber breakage. S2.2 After entering the second fine grinding stage, increase the brush roller speed to 1500r / min and maintain the same fabric feeding speed to deepen the pile density by increasing the mechanical force; S2.3 The final trimming process involves adjusting the rotation speed back to 950 r / min and using gentle friction to correct the shape of the pile tips. Throughout the process, the roller surface temperature is maintained at a constant 42°C. This temperature ensures that the fibers have suitable softening conditions while avoiding thermal damage to the material caused by high temperatures, ultimately forming a layered and uniformly delicate ultrafine pile structure.

[0025] Step 5, Post-processing: First, set the brushed fabric under low temperature relaxation conditions, and then use a non-silicone softener to soften and finish the inner layer (A yarn surface) of the fabric. Specifically, the post-processing workflow in step five: S3.1 Low temperature setting: The brushed fabric is relaxed and set at 105℃, with overfeed set at 5%. Low temperature setting avoids damage to the micro-fleece structure of wool scales by high temperature. At the same time, the relaxation treatment allows the stress in the three-layer structure to be released naturally, making the fabric softer to the touch. S3.2 Inner layer softening finish: Using a spraying method, a non-silicone softener with a mass concentration of 10g / L is sprayed onto the inner layer of the fabric (A yarn surface), with the spraying amount set at 22g / m². This differential finishing process gives the inner layer modal fibers extra softness and lubrication, thereby further enhancing the skin-friendly feel; while the outer layer wool micro-fluff is not covered by the softener, maintaining its natural micro-fluff touch and breathability, finally resulting in a fabric with a thickened modal plain weave.

[0026] Example 2 The preparation process of a fabric with thickened modal plain weave differs from that in Example 1 in that: in step one, the plasma discharge power of the natural sports wool fiber is adjusted to 80W and the treatment time is adjusted to 60 seconds; the ε-polylysine concentration of the modal fiber is adjusted to 0.6g / L, the cooling endpoint temperature is adjusted to 4℃, and the heat preservation time is adjusted to 30 minutes; the supercritical carbon dioxide treatment pressure of the carbon brushed fiber is adjusted to 16MPa, the temperature is adjusted to 50℃, the treatment time is adjusted to 35 minutes, the alternating electric field frequency is adjusted to 100Hz, and the field strength is adjusted to 10V / cm.

[0027] In step two, the twist of yarn A is adjusted to 520T / m and the yarn count is adjusted to 32Nm; the initial twist of yarn B in the S direction is adjusted to 350T / m, the re-twist twist in the Z direction is adjusted to 250T / m, the total twist is adjusted to 600T / m, and the yarn count is adjusted to 28Nm; the twist of yarn C is adjusted to 880T / m and the yarn count is adjusted to 30Nm.

[0028] In step three, the loop length of the inner layer plain weave is adjusted to 3.2mm; the loop length of the middle layer tuck is adjusted to 4.5mm; and the warp density of the outer layer plain weave is adjusted to 300 threads / 10cm, and the weft density is adjusted to 260 threads / 10cm. The total weight of the three layers of fabric is controlled at 220g / m², with the inner layer accounting for 35%, the middle layer accounting for 25%, and the outer layer accounting for 40%.

[0029] In step four, the rotation speeds of the brush rollers for the three grinding stages are adjusted as follows: 1000 r / min for the first pre-grinding stage, 1600 r / min for the second fine grinding stage, and 800 r / min for the third trimming stage; the fabric feed speed is adjusted to 6 m / min; the grinding tension is adjusted to 10 kg; and the roller surface temperature is controlled at 40℃.

[0030] In step five, the low-temperature setting temperature is adjusted to 100℃, the overfeed rate is adjusted to 4%, and the amount of inner layer softener sprayed is adjusted to 15g / m². All other process parameters and operations are the same as in Example 1.

[0031] Example 3 The preparation process of a fabric with thickened modal plain weave differs from that in Example 1 in that: in step one, the plasma discharge power of the natural sports wool fiber is adjusted to 120W and the treatment time is adjusted to 75 seconds; the ε-polylysine concentration of the modal fiber is adjusted to 0.45g / L, the cooling rate is adjusted to 0.5℃ / min, and the recovery rate is adjusted to 1.5℃ / min; the supercritical carbon dioxide treatment pressure of the carbon brushed fiber is adjusted to 14MPa, the temperature is adjusted to 45℃, the treatment time is adjusted to 30 minutes, the alternating electric field frequency is adjusted to 75Hz, and the field strength is adjusted to 7.5V / cm.

[0032] In step two, the twist of yarn A is adjusted to 680T / m and the yarn count is adjusted to 36Nm; the initial twist of yarn B in the S direction is adjusted to 450T / m, the re-twist twist in the Z direction is adjusted to 350T / m, the total twist is adjusted to 800T / m, and the yarn count is adjusted to 34Nm; the twist of yarn C is adjusted to 960T / m and the yarn count is adjusted to 36Nm.

[0033] In step three, the loop length of the inner layer plain weave is adjusted to 3.0mm; the loop length of the middle layer tuck is adjusted to 5.5mm; and the warp density of the outer layer plain weave is adjusted to 340 threads / 10cm, and the weft density is adjusted to 300 threads / 10cm. The total weight of the three layers of fabric is controlled at 280g / m², with the inner layer accounting for 30%, the middle layer accounting for 30%, and the outer layer accounting for 40%.

[0034] In step four, the rotation speeds of the brush rollers for the three grinding stages are adjusted as follows: 1200 r / min for the first pre-grinding stage, 1700 r / min for the second fine grinding stage, and 1000 r / min for the third trimming stage; the fabric feed speed is adjusted to 10 m / min; the grinding tension is adjusted to 13 kg; and the roller surface temperature is controlled at 50℃.

[0035] In step five, the low-temperature setting temperature is adjusted to 110℃, the overfeed rate is adjusted to 6%, and the amount of inner layer softener sprayed is adjusted to 25g / m². All other process parameters and operations are the same as in Example 1.

[0036] Example 4 A preparation process for a fabric with a thickened modal plain weave differs from Example 1 in that: in step one, the fiber type and weight are adjusted to: 28 parts natural sports wool fiber, 56 parts modal fiber, and 16 parts carbon fiber brushed fibers. The plasma discharge power of the natural sports wool fiber is adjusted to 90W, the treatment time to 80 seconds, and the temperature inside the device to 38℃; the ε-polylysine concentration of the modal fiber is adjusted to 0.5g / L, the initial temperature to 20℃, the cooling endpoint temperature to 3℃, and the recovery endpoint temperature to 22℃; the supercritical carbon dioxide treatment pressure of the carbon fiber is adjusted to 13MPa, the temperature to 42℃, the treatment time to 28 minutes, the alternating electric field frequency to 60Hz, and the field strength to 6V / cm.

[0037] In step two, the proportion of modal fiber in yarn A is adjusted to 88%, and the proportion of natural sports wool fiber is adjusted to 12%; the proportion of natural sports wool fiber in yarn B is adjusted to 65%, and the proportion of carbon fiber brushed fiber is adjusted to 35%; the proportion of natural sports wool fiber in yarn C is adjusted to 85%, and the proportion of modal fiber is adjusted to 15%.

[0038] In step three, the total weight of the three-layer fabric is controlled at 260 g / m², with the inner layer accounting for 32%, the middle layer accounting for 28%, and the outer layer accounting for 40%.

[0039] In step four, the rotation speeds of the brush rollers for the three grinding stages are adjusted as follows: 1050 r / min for the first pre-grinding stage, 1550 r / min for the second fine grinding stage, and 900 r / min for the third trimming stage; the fabric feed speed is adjusted to 8 m / min; the grinding tension is adjusted to 11 kg; and the roller surface temperature is controlled at 45℃.

[0040] In step five, the low-temperature setting temperature is adjusted to 108℃, the overfeed rate is adjusted to 5%, and the amount of inner layer softener sprayed is adjusted to 20g / m². All other process parameters and operations are the same as in Example 1.

[0041] Step Six: Finished Product Function Testing The finished fabrics obtained in Examples 1-4 were placed in a standard environment with a temperature of 25±2℃ and a relative humidity of 65±5% for 24 hours for equilibration, and then their quality indicators and functions were re-verified. The test data are shown in Table 2 below: Table 2 Analysis of Table 2 shows that the fabrics prepared in the four embodiments exhibit excellent performance in terms of anti-pilling, abrasion resistance, antistatic properties, and dimensional stability after washing, with all indicators meeting the design requirements. Among them, Embodiment 3, under conditions of higher fiber ratio (32 parts wool, 50 parts modal, and 18 parts carbon fiber) and higher process strength, achieves an anti-pilling grade of 4.5, a Martens abrasion resistance of 15,000 cycles, a pile height retention rate of 90%, and a front hand feel rating of 5.0, demonstrating the best overall performance. Embodiment 2, under conditions of lower process strength, still meets the design requirements, indicating that the present invention has a wide process window and good adaptability. Embodiment 4, after adjusting the fiber ratio, has an overall performance between Embodiment 1 and Embodiment 3, proving the stability and repeatability of the technical solution of the present invention. In summary, Embodiment 3 is the optimal implementation scheme of the present invention.

[0042] 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 alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fabric with a thickened modal plain weave, characterized in that, The composition and weight of the fabric are as follows: 28-32 parts natural sports wool fiber; 50-56 parts modal fiber; 13-19 parts carbon brushed fiber.

2. The fabric with a thickened modal plain weave according to claim 1, characterized in that, The fineness of the natural sports wool fiber is controlled at 16.5-18.5μm, and the crimp is controlled at 7.5-8.5 curls / cm.

3. The fabric with a thickened modal plain weave according to claim 1, characterized in that, The modal fiber has a fineness of 1.0 to 1.3 dtex, a length of 34 to 38 mm, and a wet strength of ≥4.2 cN / dtex.

4. A fabric with a thickened modal plain weave according to claim 1, characterized in that, The nano-carbon loading of the carbon brushed fiber is controlled at 1.5-1.8 wt%, and the fiber diameter is controlled at 1.8-2.5D.

5. A manufacturing process for a fabric with a thickened modal plain weave, characterized in that, The preparation of a fabric formulation with a thickened modal plain weave according to claim 1 includes the following steps: Step 1: Ingredient preparation: Use natural sports wool fiber, modal fiber and carbon brushed fiber as raw materials, weigh them according to the formula weight parts and pre-treat them; Step 2, Sectional Single Yarn Spinning: The pretreated natural sports wool fiber, modal fiber and carbon brushed fiber are spun into three different yarns with different structures and functions: A yarn, B yarn and C yarn. Step 3, Gradient Weaving: Using a double-sided multi-layer loom, yarns A, B, and C are woven in a three-layer structure (inner-middle-outer) in one pass to obtain the complete fabric. The total weight of the three layers is controlled between 220 and 280 g / m², with the inner layer accounting for 30% to 35%, the middle layer accounting for 25% to 30%, and the outer layer accounting for 35% to 45%. Step 4, Outer Layer Directional Micro-Fluffing: The outer layer of the fabric is subjected to a three-stage progressive brushing process using ceramic fiber brush rollers. Step 5, Post-processing: First, set the brushed fabric under low temperature relaxation conditions, and then use a non-silicone softener to soften and finish the inner layer of the fabric. Step Six: Finished Product Functional Testing: After the finished fabric has been shaped and placed in a standard environment for equilibration, quality indicators and functional re-testing verification are performed.

6. The manufacturing process of a fabric with a thickened modal plain weave according to claim 5, characterized in that, The component pretreatment in step one: (1) Place natural sports wool fibers in a low-frequency ultrasonic-assisted low-temperature plasma treatment device. The treatment medium is a mixture of argon gas and trace water vapor with a volume ratio of 95:

5. The plasma discharge power is controlled at 80-100W, the treatment time is 60-90 seconds, and the temperature inside the device is controlled at 35-36℃. (2) The modal fiber was placed in an ice-water mixing bath. The mixing bath was a mixed solution of deionized water and ε-polylysine with a bath ratio of 1:20 to 1:

25. The concentration of ε-polylysine was controlled at 0.3 to 0.4 g / L. The treatment process adopted a programmed temperature control: the initial temperature was 18 to 20°C, the temperature was lowered to 2 to 4°C at a rate of 0.3 to 0.5°C / min, and the temperature was kept for 30 to 45 minutes. Then the temperature was raised to 20 to 22°C at a rate of 1 to 3°C / min, and the temperature was kept for 15 to 18 minutes. The entire treatment process was accompanied by intermittent low-speed stirring at a speed of 30 to 45 r / min and stirring for 1 minute and stopping for 3 minutes. (3) Place the carbon fiber in a supercritical carbon dioxide treatment vessel and treat it for 20 to 30 minutes under supercritical conditions of 12 to 14 MPa and 40 to 45 °C. During the supercritical treatment, apply an alternating electric field with a frequency of 50 to 80 Hz and a field strength of 5 to 8 V / cm. After the treatment, gradually depressurize to atmospheric pressure at a rate of 3 to 5 MPa / min.

7. The manufacturing process of a fabric with a thickened modal plain weave according to claim 5, characterized in that, Step two involves the sectional single yarn spinning process: (1) Inner layer skin-friendly yarn: 82% to 88% of modal fiber and 12% to 18% of natural sports wool fiber are mixed and spun with low twist, with twist controlled at 520 to 620 T / m and yarn count of 32 to 38 Nm to obtain inner layer A yarn; (2) Intermediate layer functional yarn: 55% to 65% of natural sports wool fiber and 35% to 45% of carbon brushed fiber are spun using S / Z bidirectional twisting method: first set the twist to 350 to 450 T / m and initially twist in the S direction; then adjust the twist to 250 to 350 T / m and retwist in the Z direction, with the total twist controlled at 600 to 800 T / m and the yarn count 28 to 34 Nm to obtain intermediate layer B yarn; (3) Outer layer fleece yarn: 78% to 85% of natural sports wool fiber and 15% to 22% of modal fiber are mixed and spun with high twist, with twist controlled at 980 to 1020 T / m and yarn count of 30 to 36 Nm to obtain outer layer C yarn.

8. The manufacturing process of a fabric with a thickened modal plain weave according to claim 5, characterized in that, The gradient weaving process in step three: S1.1 Inner layer: Made with yarn A as the weft yarn, using a plain weft knit structure, with a loop length of 2.8–3.0 mm; S1.2, Intermediate layer: Using B yarn as the connecting yarn, the inner layer and outer layer are connected by a tuck weave, with a tuck length of 4.8-5.4mm; S1.3 Outer layer: Made of C yarn as warp, with a plain weave structure, warp density of 310-330 threads / 10cm and weft density of 270-290 threads / 10cm.

9. The manufacturing process of a fabric with a thickened modal plain weave according to claim 5, characterized in that, The outer layer directional microfibrilation process in step four: S2.1 The first pre-grinding process is carried out under low tension of 10-13 kg, with a brush roller speed of 1000-1200 r / min and a fabric feed speed of 6-8 m / min to build the basic texture. S2.2 After entering the second fine grinding stage, increase the brush roller speed to 1500-1600 r / min and maintain the same fabric feeding speed; S2.3 In the final trimming process, the rotation speed is adjusted back to 900-1000 r / min. Throughout the process, the surface temperature of the roller is kept constant in the range of 40-45℃, ultimately forming a distinct and uniform ultrafine microfiber structure.

10. The manufacturing process of a fabric with a thickened modal plain weave according to claim 5, characterized in that, The post-processing procedure in step five: S3.1 Low temperature setting: The brushed fabric is relaxed and set at 100-105℃, with overfeed set between 4% and 6%; S3.2 Inner layer softening finishing: Using a spraying method, a non-silicone softener with a mass concentration of 10-12 g / L is sprayed onto the inner layer of the fabric, with the spraying amount set to 20-25 g / m², finally obtaining a fabric with a thickened modal plain weave.

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