An ultra-thin high-softness polyester fabric

Abstract

This utility model discloses an ultra-thin, highly flexible polyester fabric, relating to the field of polyester fabric technology. The ultra-thin, highly flexible polyester fabric includes a top layer, a middle layer, and a bottom layer. The top layer is woven from ultra-fine denier polyester filaments. The middle layer is an elastic support layer formed by interlacing hollow polyester staple fibers, with the hollow fibers arranged in a spiral pattern and filled with flexible aerogel microspheres. The bottom layer is a porous polyester mesh base fabric, with the mesh openings on the bottom layer fabric arranged in a gradient from the outside to the inside. This utility model, through a three-layer composite structure design, combining ultra-fine denier filaments, hollow fiber-filled aerogel, and a porous mesh base fabric, along with a special connection method, achieves multiple superior properties including ultra-thinness, high flexibility, moisture wicking and breathability, and skin-friendly comfort.

Description

Technical Field

[0001] This utility model relates to the field of polyester fabric technology, and in particular to an ultra-thin, highly soft polyester fabric. Background Technology

[0002] Polyester (polyester fiber) fabric is a synthetic fiber fabric made from polyethylene terephthalate (PET). Traditional polyester fabrics have many limitations in practical applications due to their relatively large fiber diameter (generally above 1.5D) and simple structure.

[0003] First, conventional polyester fabrics are typically thicker than 0.5mm, which is insufficient to meet the demands of modern clothing for lightweight properties. Second, due to the high rigidity of the fibers and insufficient surface smoothness, the fabric feels stiff and has poor skin-friendliness. Furthermore, the breathability and moisture-wicking properties of existing polyester fabrics are often difficult to balance, affecting the comfort of wearing them. Utility Model Content

[0004] This utility model provides an ultra-thin, highly flexible polyester fabric, comprising a top layer, a middle layer, and a bottom layer. The top layer is woven from ultra-fine denier polyester filaments. The middle layer is formed by interlacing hollow polyester staple fibers to create an elastic support layer. The hollow fibers are arranged in a spiral shape and filled with flexible aerogel microspheres. The bottom layer is a porous polyester mesh base fabric with the mesh openings on the bottom layer distributed in a gradient from the outside to the inside.

[0005] Preferably, the outer fabric and the middle fabric are bridged by an elastic fiber layer, which is a wavy polyester monofilament with a diameter of 0.1-0.3μm and a density of 5-10 strands / mm. 2 The density is interspersed between the two layers.

[0006] Preferably, an elastic buffer strip is provided between the bottom layer fabric and the middle layer fabric. The elastic buffer strip is a polyester and spandex blended strip with a width of 0.5-1mm, arranged in parallel with a spacing of 5-10mm.

[0007] Preferably, the edge of the bottom mesh base fabric is covered with a silicone rubber film with a thickness of 0.01-0.05 mm.

[0008] Preferably, the surface of the outer fabric is distributed with a plurality of microporous honeycomb structures, the microporous honeycomb having hexagonal micropores with a diameter of 1-3 μm.

[0009] Preferably, the microporous honeycomb has longitudinal grooves etched into the pore walls with a depth of 100-300 nm.

[0010] Preferably, the microporous honeycomb structures are interconnected through fine channels to form a three-dimensional breathable network.

[0011] Preferably, the axial direction of the hollow polyester staple fiber in the middle layer fabric forms an angle of 30°-60° with the fabric plane.

[0012] Preferably, the joint surfaces of the top layer fabric, the middle layer fabric, and the bottom layer fabric are all interlocked in a serrated pattern, with an interlocking depth of 0.05-0.1 mm and an interlocking density of 20-30 teeth / cm.

[0013] Preferably, the mesh edge is provided with a flexible chamfer structure, the chamfer structure is a rounded transition with a radius of curvature of 0.05-0.1mm and a chamfer angle of 30°-45°.

[0014] This utility model provides an ultra-thin, highly flexible polyester fabric, which, compared with the prior art, offers the following advantages:

[0015] 1. This utility model achieves excellent wearing comfort and functionality through the synergistic effect of a three-layer composite structure. The outer layer fabric, with its ultra-fine denier filaments and dual structure design of microporous honeycomb and nano-grooves, significantly enhances the fabric's skin-friendliness and moisture-wicking properties. The middle layer fabric uses hollow polyester staple fibers filled with flexible aerogel microspheres, providing excellent elasticity and resilience while ensuring the fabric's lightweight characteristics. The bottom layer fabric's porous mesh base fabric, with its gradient mesh design, achieves good breathability and structural stability. The three-layer structure, through special connection methods such as elastic fiber bridging and serrated interlocking, ensures the overall softness and durability of the fabric, significantly improving wearing comfort.

[0016] 2. This invention avoids the sharp edges of traditional fabric meshes by using flexible chamfering, significantly improving comfort against the skin. The microporous honeycomb network forms a three-dimensional breathable structure, allowing sweat to be quickly wicked away and keeping the wearer dry. Special designs such as elastic cushioning bands and silicone rubber membranes further optimize the overall softness and edge comfort of the fabric. These innovative structures work together to give the fabric an ultra-thin profile while providing a soft touch and wearing comfort unmatched by ordinary polyester fabrics. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model;

[0019] Figure 2This is a top view of the overall structure of an embodiment of the present utility model;

[0020] Figure 3 This is an embodiment of the present utility model. Figure 2 Cross-sectional view along structure AA;

[0021] Figure 4 This is a top view schematic diagram of the surface fabric structure of an embodiment of the present utility model;

[0022] Figure 5 This is a schematic diagram of the middle layer fabric structure according to an embodiment of the present utility model;

[0023] Figure 6 This is a schematic diagram of the flexible aerogel microsphere structure according to an embodiment of the present invention;

[0024] Figure 7 This is a top view schematic diagram of the bottom fabric structure of an embodiment of the present utility model;

[0025] Figure 8 This is a side view of the sawtooth structure according to an embodiment of the present invention.

[0026] Figure label:

[0027] 1. Top layer fabric; 2. Middle layer fabric; 3. Bottom layer fabric; 4. Elastic fiber layer; 5. Elastic cushioning strip; 6. Microporous honeycomb; 7. Groove; 8. Flexible aerogel microspheres; 9. Mesh; 10. Silicone rubber membrane; 11. Serration; 12. Microchannel. Detailed Implementation

[0028] The following detailed description, in conjunction with the accompanying drawings, outlines some embodiments of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0029] Please refer to Figures 1-8 This utility model provides an ultra-thin, highly flexible polyester fabric, comprising a top layer fabric 1, a middle layer fabric 2, and a bottom layer fabric 3. The top layer fabric 1, middle layer fabric 2, and bottom layer fabric 3 form a fabric with a total thickness of 0.1-0.3 mm. The top layer fabric 1 accounts for 15%-20%, the middle layer fabric 2 accounts for 40%-50%, and the bottom layer fabric 3 accounts for 30%-40%, making the fabric lighter and thinner.

[0030] The outer fabric 1 is woven from 0.3-0.8D ultra-fine denier polyester filaments with a single filament diameter ≤5μm. The surface has a multi-level rough structure, which significantly reduces the stickiness of the skin. The surface of the outer fabric 1 is distributed with several microporous honeycomb 6. The microporous honeycomb 6 has hexagonal micropores with a diameter of 1-3μm. The hexagonal microporous honeycomb 6 simulates the structure of human sweat glands, realizes capillary effect moisture wicking, and provides space for moisture to be temporarily stored.

[0031] The microporous honeycomb 6 is interconnected by fine channels 12 to form a three-dimensional breathable network, which not only enhances the overall breathability of the fabric, but also forms a three-dimensional moisture-wicking structure that can quickly wick away sweat and keep the wearer dry and comfortable. In addition, longitudinal grooves 7 with a depth of 100-300nm are etched in the pore walls of the microporous honeycomb 6 to reduce the coefficient of friction between fibers.

[0032] The middle layer fabric 2 is formed by interlacing hollow polyester staple fibers to form an elastic support layer. The hollow fibers are arranged in a spiral shape, which significantly improves the elasticity of the fabric and enhances the three-dimensional support effect. In addition, the hollow fibers are filled with flexible aerogel microspheres 8. The flexible aerogel microspheres 8 have a diameter of 1-5μm and occupy 10%-20% of the hollow cavity volume, realizing multi-directional elastic response, enhancing anti-fatigue performance, and improving wearing comfort.

[0033] The hollow polyester staple fiber in the middle layer fabric 2 forms an angle of 30°-60° with the fabric plane, which improves the fit of the fabric and reduces movement restriction.

[0034] The bottom fabric 3 is a porous polyester mesh base fabric. The mesh holes 9 on the bottom fabric 3 are distributed in a gradient from the outside to the inside, with denser mesh holes 9 at the edges and sparser mesh holes 9 in the center, which enhances structural stability, forms an efficient breathable main channel, and prevents condensation and water accumulation in the gradient transition area.

[0035] The edges of the mesh 9 feature a flexible chamfered structure with a rounded transition, a curvature radius of 0.05-0.1mm, and a chamfer angle of 30°-45°. This effectively avoids the sharpness of the edges of traditional mesh 9, significantly improving the comfort of the fabric against the skin without affecting breathability.

[0036] The outer fabric 1 and the middle fabric 2 are bridged by an elastic fiber layer 4, which is a wavy polyester monofilament with a diameter of 0.1-0.3μm and a density of 5-10 strands / mm. 2 The density of the fibers is interspersed between the two layers, which allows the fabric to maintain its ultra-thin characteristics while achieving an elastic connection between the layers. This greatly improves the overall flexibility and anti-delamination performance of the fabric. The wavy fiber structure can provide progressive rebound when stretched, ensuring freedom of movement and preventing deformation when worn.

[0037] An elastic cushioning band 5 is provided between the bottom layer fabric 3 and the middle layer fabric 2. The elastic cushioning band 5 is a polyester and spandex blended strip with a width of 0.5-1mm and arranged in parallel with a spacing of 5-10mm. This intermittent elastic cushioning band 5 design not only ensures the basic support of the fabric, but also achieves excellent pressure distribution effect through local elastic areas. It can effectively reduce the feeling of restraint, especially in joint movement areas, while avoiding the problem of reduced breathability caused by traditional overall elastic layers.

[0038] The bottom layer fabric 3 has a silicone rubber soft film 10 wrapped around its edge. The silicone rubber soft film 10 is 0.01-0.05mm thick. The ultra-thin and flexible edge wrapping design effectively prevents wear and fiber shedding from the edges of the mesh 9, while maintaining the soft touch of the fabric edges so that there will be no friction discomfort when wearing it. At the same time, the precise thickness control of 0.01-0.05mm ensures that the overall breathability and flexibility of the fabric are not affected.

[0039] The bonding surfaces of the top layer fabric 1, the middle layer fabric 2, and the bottom layer fabric 3 are all interlocked with 11-tooth serrations, with an interlocking depth of 0.05-0.1mm and an interlocking density of 20-30 teeth / cm. This high-precision 11-tooth interlocking structure creates a huge interlayer bonding area, which increases the peel strength between the layers by more than 3 times. At the same time, the 11-tooth serration design allows for slight displacement between the layers, giving the fabric excellent dynamic bending performance while maintaining structural stability, ensuring that it remains flat and wrinkle-free after repeated stretching and folding.

[0040] In summary, the working principle of this utility model embodiment of an ultra-thin, highly soft polyester fabric is as follows: Ultra-thinness and high softness are achieved through the synergistic effect of a three-layer composite structure: the outer fabric 1 uses ultra-fine denier filaments combined with a microporous honeycomb structure 6 and nano-groove 7 to enhance moisture wicking and skin-friendliness; the middle fabric 2 uses spirally arranged fibers filled with air gel to provide elastic support; and the bottom fabric 3 uses a gradient mesh design 9 to optimize breathability and stability. The interlocking of each layer is enhanced by an elastic fiber layer 4, elastic cushioning bands 5, and serrations 11, allowing the fabric to possess excellent elasticity, breathability, and comfort at a thickness of 0.1-0.3mm.

[0041] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An ultra-thin, highly soft polyester fabric, comprising a top layer fabric (1), a middle layer fabric (2), and a bottom layer fabric (3), characterized in that: The outer fabric (1) is woven from ultra-fine denier polyester filaments. The middle fabric (2) is formed by interlacing hollow polyester short fibers to form an elastic support layer. The hollow fibers are arranged in a spiral shape and are filled with flexible aerogel microspheres (8). The bottom fabric (3) is a porous polyester mesh base fabric. The mesh holes (9) on the bottom fabric (3) are distributed in a gradient from the outside to the inside.

2. The ultra-thin, highly flexible polyester fabric according to claim 1, characterized in that: The outer fabric (1) and the middle fabric (2) are bridged by an elastic fiber layer (4), which is a wavy polyester monofilament with a diameter of 0.1-0.3μm and 5-10 strands / mm. 2 The density is interspersed between the two layers.

3. The ultra-thin, highly flexible polyester fabric according to claim 2, characterized in that: An elastic buffer strip (5) is provided between the bottom layer fabric (3) and the middle layer fabric (2). The elastic buffer strip (5) is a polyester and spandex blended strip with a width of 0.5-1mm and arranged in parallel with a spacing of 5-10mm.

4. The ultra-thin, highly flexible polyester fabric according to claim 3, characterized in that: The edge of the mesh base fabric of the bottom layer (3) is covered with a silicone rubber soft film (10), and the silicone rubber soft film (10) has a thickness of 0.01-0.05mm.

5. The ultra-thin, highly flexible polyester fabric according to claim 4, characterized in that: The surface of the outer fabric (1) is distributed with a number of microporous honeycomb (6), the microporous honeycomb (6) having hexagonal micropores with a diameter of 1-3 μm.

6. The ultra-thin, highly flexible polyester fabric according to claim 5, characterized in that: The microporous honeycomb (6) has longitudinal grooves (7) with a depth of 100-300 nm etched inside the pore walls.

7. The ultra-thin, highly flexible polyester fabric according to claim 6, characterized in that: The microporous honeycomb (6) are interconnected through fine channels (12) to form a three-dimensional breathable network.

8. The ultra-thin, highly flexible polyester fabric according to claim 1, characterized in that: The hollow polyester staple fiber in the middle layer fabric (2) forms an angle of 30°-60° with the fabric plane.

9. The ultra-thin, highly flexible polyester fabric according to claim 7, characterized in that: The mating surfaces of the top layer fabric (1), middle layer fabric (2) and bottom layer fabric (3) are all interlocked in a sawtooth (11) shape, with an interlocking depth of 0.05-0.1mm and an interlocking density of 20-30 teeth / cm.

10. The ultra-thin, highly flexible polyester fabric according to claim 1, characterized in that: The mesh (9) has a flexible chamfered structure at its edge. The chamfered structure has a rounded transition with a radius of curvature of 0.05-0.1 mm and a chamfer angle of 30°-45°.

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