A soft wear-resistant microfiber fabric

Abstract

The utility model discloses a kind of soft wear-resisting microfiber fabrics, including the base cloth layer, soft buffer layer, microfiber main body layer, wear-resisting reinforcing layer and surface protective layer sequentially compounded from bottom to top.It is knitted by polyester filament and spandex covering silk to be made into base cloth layer, and front is dense area, back is loose area, provides elastic support and dimensional stability.Soft buffer layer is formed honeycomb unit by microfiber needle punching, and honeycomb unit includes central region and edge region, and central region fiber density is lower than edge region fiber density, and it is balanced by density gradient distribution to be lightweight and impact resistance performance.The microfiber main body layer includes surface island silk layer, intermediate high shrinkage layer and bottom island silk layer, and forms pile layer by raising and grinding processing, and intermediate high shrinkage layer generates shrinkage when shaping and makes fabric form three-dimensional fluffy structure.The utility model fabric has excellent softness, wear resistance, elasticity and waterproof and breathable performance, and is suitable for high-performance sportswear, outdoor equipment and other fields.

Description

Technical Field

[0001] This utility model relates to the field of textile materials technology, specifically to a soft and wear-resistant microfiber fabric, and more particularly to a microfiber fabric with a multi-layer composite structure that combines a soft feel with high wear resistance, suitable for high-performance sportswear, outdoor equipment, footwear, bags and other fields. Background Technology

[0002] Currently, the main technical defects of microfiber fabrics on the market are as follows: Firstly, traditional microfiber fabrics mostly use a single base fabric structure and lack a cushioning layer design. When subjected to impact or pressure, they are prone to localized deformation, affecting service life and comfort. For example... Figure 2 As shown, the base fabric layer in the prior art usually adopts a homogeneous warp knitting structure, with the weaving structure of the front, middle and back sides being basically the same, lacking targeted functional zoning design, which makes it difficult to balance abrasion resistance and comfort in the fabric.

[0003] Secondly, the existing abrasion-resistant treatment methods for microfiber fabrics are relatively simple, usually using an overall abrasion-resistant coating. Although this can improve abrasion resistance, it will seriously affect the breathability and softness of the fabric, and the bonding strength between the coating and the substrate is insufficient, making it easy for delamination to occur.

[0004] Secondly, the interlayer bonding process of traditional microfiber fabrics often uses a full-coverage adhesive coating method. Although this can ensure the interlayer bonding strength, it will block the fabric pores, seriously affecting the breathability. At the same time, the presence of adhesive will make the fabric stiff, reducing its softness and elasticity.

[0005] In addition, such as Figure 4 As shown, the cushioning layer in the prior art usually adopts a uniformly distributed fiber structure with a fiber density that is basically the same throughout the area and lacks gradient design. While providing a cushioning effect, this structure increases the overall weight and stiffness of the fabric, making it difficult to achieve an effective balance between lightweight and impact resistance.

[0006] At the same time, such as Figure 6 As shown, the existing microfiber main body layer mostly adopts a single-layer or simple double-layer weaving structure. There is a lack of functional synergy between the layers, and it is impossible to form a three-dimensional fluffy structure through the shrinkage effect, which makes it difficult to achieve the ideal effect in terms of fabric pile density and touch.

[0007] Furthermore, existing microfiber fabrics also have shortcomings in terms of waterproof and stain-resistant performance. Traditional waterproofing treatments mainly rely on coatings or films, but these methods often affect the fabric's breathability and feel. How to maintain waterproof performance while preserving the fabric's breathability and softness is a problem that has not yet been well solved by current technology. Summary of the Invention

[0008] The technical problem to be solved by this utility model is to provide a soft and wear-resistant microfiber fabric, which aims to overcome the problem that existing microfiber fabrics cannot achieve both softness and wear resistance. It achieves the organic unity of soft feel and high wear resistance through a multi-layer composite structure.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: A soft and durable microfiber fabric comprising the following structural layers layered sequentially from bottom to top: The base fabric layer is made of warp-knitted polyester filament and spandex covered yarn, with a dense area on the front and a loose area on the back; A soft buffer layer is formed by needle punching ultrafine fibers into honeycomb units, each honeycomb unit comprising a central region and an edge region, wherein the fiber density in the central region is lower than that in the edge region. The microfiber main layer includes a surface island fiber layer, a middle high-shrinkage layer, and a bottom island fiber layer, which are napped to form a pile layer. The wear-resistant reinforcement layer includes a TPU film layer and a wear-resistant lattice, wherein the wear-resistant lattice is formed of a polyurethane material containing silicon carbide particles; Surface protective layer, including a pre-textured thin film layer and a waterproof coating.

[0010] Furthermore, the base fabric layer is warp-knitted using a double needle bed, with a rib knit in the dense area on the front and a rib knit in the loose area on the back. This design with different weave structures on the front and back achieves a balance between abrasion resistance and comfort, while the spandex covering yarn provides good elastic recovery properties.

[0011] Furthermore, the honeycomb cells of the soft buffer layer are formed through a partitioned needle punching process. Through the density gradient distribution of the honeycomb structure, the central soft area provides comfort, while the edge reinforced areas prevent structural collapse, achieving lightweight while maintaining good impact resistance.

[0012] Furthermore, in the microfiber main body layer, the surface island yarn layer and the bottom island yarn layer are fully loop woven, while the middle high-shrinkage layer is semi-loop woven with a mixture of high-shrinkage yarn, island yarn and spandex yarn.

[0013] Furthermore, the high-shrinkage yarn in the intermediate high-shrinkage layer shrinks during setting, giving the fabric a three-dimensional, fluffy structure; the island-island yarn is treated with alkali to reduce its weight, forming microfiber. In the three-layer structure, the full loop weave of the top and bottom layers provides stability, the semi-loop weave of the middle layer, combined with the high-shrinkage yarn, produces a shrinkage effect, giving the fabric a three-dimensional, fluffy structure, and the island-island yarn, after alkali reduction, forms microfiber, giving the fabric a delicate touch.

[0014] Furthermore, the abrasion-resistant dot matrix is ​​arranged in a hexagonal pattern, with a dot matrix coverage of 30-45%. The dot matrix design achieves optimal coverage through hexagonal arrangement, and the silicon carbide microparticles significantly improve abrasion resistance, maintaining the fabric's softness and breathability while ensuring abrasion resistance.

[0015] Furthermore, the pre-pressed texture of the thin film layer in the surface protective layer is intersected with the napping direction of the pile layer. The intersection of the pre-pressed texture of the thin film with the pile direction enhances the anti-slip properties and the visual three-dimensional effect.

[0016] Furthermore, the interlayer bonding methods are as follows: the base fabric layer and the soft cushioning layer are flame-bonded; the soft cushioning layer and the microfiber main layer are dot-coated; the microfiber main layer and the abrasion-resistant reinforcement layer are bonded together using TPU scraping film; and the abrasion-resistant reinforcement layer and the surface protective layer are bonded together using hot pressing. These different interlayer bonding processes ensure both the interlayer bonding strength and maintain the fabric's breathability and softness.

[0017] Furthermore, the dotted adhesive is water-based polyurethane adhesive, and the flame bonding is adhesive-free bonding.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention achieves a synergistic combination of softness and high abrasion resistance through a five-layer composite structure. The fabric boasts a 15% elastic recovery rate, a pile density of 2600 threads / cm², and a 38% abrasion-resistant dot matrix coverage. The soft cushioning layer employs a honeycomb structure design, achieving a balance between lightweight and impact resistance through density gradient distribution. The three-layer structure of the microfiber main layer utilizes the shrinkage effect of high-shrinkage yarns to create a three-dimensional, fluffy structure, while the island-island yarns are processed into ultrafine fibers, giving the fabric a delicate touch. The abrasion-resistant reinforcement layer uses a composite design of TPU film and silicon carbide dot matrix, significantly improving surface abrasion resistance while maintaining the fabric's softness and breathability through the dot matrix arrangement. Differentiated processes such as flame bonding, dot coating, TPU scraping film formation, and hot-pressing lamination are used between layers to ensure interlayer bonding strength while maintaining the fabric's breathability and softness. This invention's fabric has excellent waterproof and breathable properties, making it suitable for high-performance sportswear, outdoor equipment, and other fields. Attached Figure Description

[0019] The invention will now be further described with reference to the accompanying drawings.

[0020] Figure 1 This is a schematic diagram of the overall structure of the soft and wear-resistant microfiber fabric of the present invention; Figure 2 This is a schematic diagram of the weaving structure of the base fabric layer in existing technology; Figure 3 This is a schematic diagram of the weaving structure of the base fabric layer of the present invention; Figure 4This is a schematic diagram of the fiber distribution in a soft buffer layer in existing technology; Figure 5 This is a schematic diagram of the honeycomb unit structure of the soft buffer layer of the present invention; Figure 6 This is a schematic diagram of the braiding structure of the microfiber main body layer in existing technology; Figure 7 This is a schematic diagram of the three-layer structure of the ultrafiber main body layer of the present invention.

[0021] Explanation of reference numerals in the attached figures: 1-Base layer, 11-Dense zone, 12-Loose zone; 2-Soft buffer layer, 21-Honeycomb unit, 22-Central area, 23-Edge area; 3-Microfiber main body layer, 31-Surface island silk layer, 32-Intermediate high-shrinkage layer, 33-Bottom island silk layer, 34-Fleece layer; 4-Abrasion-resistant reinforcing layer, 41-TPU film layer, 42-Abrasion-resistant dot matrix; 5-Surface protective layer, 51-Thin film layer, 52-Waterproof coating. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0023] Example 1: Figure 1 As shown, a soft and durable microfiber fabric employs a five-layer composite structure, consisting of a base fabric layer 1, a soft cushioning layer 2, a microfiber main body layer 3, an abrasion-resistant reinforcement layer 4, and a surface protective layer 5, with a total thickness of approximately 2.4 mm. This fabric achieves a harmonious balance between a soft feel and high abrasion resistance through the synergistic function of each layer: the base fabric layer provides elastic support and dimensional stability; the soft cushioning layer uses a honeycomb structure to provide impact cushioning; the microfiber main body layer forms a high-density pile through a three-layer island-of-the-sea fiber structure, giving the fabric a delicate touch; the abrasion-resistant reinforcement layer uses a TPU film combined with a silicon carbide dot matrix composite, significantly improving surface abrasion resistance; and the surface protective layer provides waterproof and stain-resistant properties. Different processes, such as flame bonding, dot-matrix coating, TPU coating film formation, and hot-pressing, are used between the layers to ensure interlayer bonding strength while maintaining the fabric's breathability and softness. This fabric features a 15% elastic recovery rate, a pile density of 2600 threads / cm², a 38% abrasion-resistant dot matrix coverage, and excellent waterproof and breathable properties, making it suitable for high-performance sportswear, outdoor equipment, and other fields.

[0024] The specific structure of each layer is as follows, see below. Figures 1-5 : Base layer 1: Made of 150D polyester filament and 40D spandex covering yarn in a ratio of 85:15, double needle bed warp knitting. The dense area 11 on the front side has 2×2 rib knit, and the loose area 12 on the reverse side has 1×3 rib knit, with a thickness of 0.6mm. The different weave structures on the front and back sides achieve a balance between abrasion resistance and comfort, and the spandex covering yarn provides 15% elastic recovery.

[0025] Soft cushioning layer 2: Made of 0.1 denier polyester microfiber with a needle-punching density of 800 needles / cm², forming honeycomb units 21 with a unit diameter of 4mm. The fiber density in the central area 22 of the unit is reduced by 20%, while the fiber density in the edge area 23 of the unit is increased by 15%, with a thickness of 0.4mm. The honeycomb structure achieves lightweight while maintaining good impact resistance through a density gradient distribution. The soft central area provides comfort, while the reinforced edge area prevents structural collapse.

[0026] The microfiber main body layer 3 consists of three layers: the outermost layer 31, made of 100D / 72F island-island composite yarn (island-island ratio 30:70), fully loop-woven, with a thickness of 0.25mm; the middle high-shrinkage layer 32, made of 150D / 48F high-shrinkage yarn (shrinkage rate 18%), 100D / 72F island-island yarn, and 40D spandex yarn, in a ratio of 40:45:15, semi-loop-woven, with a thickness of 0.30mm; the bottom layer 33, with the same structure as the outermost layer, with a thickness of 0.25mm; and the napped layer 34, formed by brushing and napping, with a pile density of 2600 fibers / cm² and a total thickness of 0.8mm. In this three-layer structure, the fully loop-woven outer and bottom layers provide stability, while the semi-loop-woven middle layer, combined with the high-shrinkage yarn, produces an 18% shrinkage during setting, resulting in a three-dimensional, fluffy structure. The island-island yarn is alkali-reduced to form 0.1 denier microfiber.

[0027] Abrasion-resistant reinforcement layer 4: The TPU film layer 41 is coated with thermoplastic polyurethane with a thickness of 0.25mm; the abrasion-resistant dot matrix 42 is screen-printed with a polyurethane emulsion containing 10% silicon carbide particles (100 mesh), forming a hexagonal arrangement with a dot diameter of 1.5mm, a dot height of 0.15mm, and a dot spacing of 2.5mm, with a dot matrix coverage of 38% and a total thickness of 0.4mm. The TPU film layer provides overall protection, and the dot matrix design achieves optimal coverage through hexagonal arrangement. The silicon carbide particles significantly improve abrasion resistance, maintaining the fabric's softness and breathability while ensuring abrasion resistance.

[0028] Surface protective layer 5: PETG film 51, 0.13 mm thick, with a pre-embossed texture depth of 25 μm, intersecting the pile direction of the fleece layer 34 at a 45° angle; waterproof coating 52 is a silicone waterproofing agent, with a dry film thickness of 6 μm and a total thickness of 0.15 mm. The pre-embossed texture of the PETG film intersects the pile direction at a 45° angle, enhancing anti-slip properties and visual three-dimensionality, while the silicone coating provides durable waterproof and stain-resistant performance.

[0029] Interlayer bonding: The base fabric layer 1 and the soft cushioning layer 2 are flame-bonded, instantly melting the surface fibers to achieve glue-free bonding; the soft cushioning layer 2 and the microfiber main body layer 3 are bonded with dot-matrix adhesive (water-based polyurethane adhesive) to maintain breathability; the microfiber main body layer 3 and the abrasion-resistant reinforcing layer 4 are bonded with TPU to form a film, completing the bonding and film formation in one step; the abrasion-resistant reinforcing layer 4 and the surface protective layer 5 are bonded by hot pressing.

[0030] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

[0031] For example, the ratio of polyester filaments and spandex covering yarns, denier number, and warp knitting structure in the base fabric layer can be adjusted according to actual needs; the honeycomb unit size, needle punching density, and fiber density difference between the central and edge areas in the soft cushioning layer can be varied within a reasonable range; the ratio of island yarns in the microfiber main body layer, the shrinkage rate of high-shrinkage yarns, and the thickness of the three-layer structure can be optimized according to application requirements; the content, mesh number, and shape, size, and spacing of silicon carbide particles in the wear-resistant reinforcing layer can be appropriately adjusted; the film material, thickness, and pre-pressing texture angle of the surface protective layer can be selected according to specific application scenarios; and the parameters of the interlayer composite process can also be optimized and adjusted according to equipment conditions and production requirements.

[0032] This invention, through a five-layer composite structure and the coordinated function of each layer, successfully solves the technical challenge of balancing softness and abrasion resistance in microfiber fabrics. It provides a new technical solution for the development of high-performance microfiber fabrics and has good application prospects and promotional value.

Claims

1. A soft and durable microfiber fabric, characterized in that, The following structural layers are combined sequentially from bottom to top: The base fabric layer (1) is made of polyester filament and spandex covered yarn warp knitting, with a dense area (11) on the front and a loose area (12) on the back. The soft buffer layer (2) is formed by needle punching with ultra-fine fibers to form honeycomb units (21). The honeycomb units include a central area (22) and an edge area (23). The fiber density in the central area is lower than that in the edge area. The microfiber main body layer (3) includes a surface island fiber layer (31), a middle high-shrinkage layer (32) and a bottom island fiber layer (33), which are then napped to form a pile layer (34). The wear-resistant reinforcement layer (4) includes a TPU film layer (41) and a wear-resistant matrix (42), wherein the wear-resistant matrix is ​​formed of a polyurethane material containing silicon carbide particles; The surface protective layer (5) includes a pre-textured thin film layer (51) and a waterproof coating (52).

2. The soft and wear-resistant microfiber fabric according to claim 1, characterized in that, The base fabric layer (1) is made of double needle bed warp knitting, with the dense area (11) on the front side being rib knit and the loose area (12) on the back side being rib knit.

3. The soft and wear-resistant microfiber fabric according to claim 1, characterized in that, The honeycomb cells (21) of the soft buffer layer (2) are formed by a partitioned needle punching process.

4. The soft and wear-resistant microfiber fabric according to claim 1, characterized in that, In the superfiber main body layer (3), the surface island yarn layer (31) and the bottom island yarn layer (33) are fully loop woven, and the middle high-shrinkage layer (32) is semi loop woven with a mixture of high-shrinkage yarn, island yarn and spandex yarn.

5. The soft and wear-resistant microfiber fabric according to claim 4, characterized in that, The high-shrinkage yarn in the intermediate high-shrinkage layer (32) shrinks during the shaping process, making the fabric form a three-dimensional fluffy structure; the island yarn is formed into ultrafine fiber after alkali reduction treatment.

6. The soft and abrasion-resistant microfiber fabric according to claim 1, characterized in that, The wear-resistant lattice (42) is arranged in a hexagonal pattern, with a lattice coverage of 30-45%.

7. The soft and wear-resistant microfiber fabric according to claim 1, characterized in that, The pre-pressed texture of the thin film layer (51) in the surface protective layer (5) is intersected with the roughening direction of the flock layer (34).

8. The soft and abrasion-resistant microfiber fabric according to claim 1, characterized in that, The interlayer connection method is as follows: the base fabric layer (1) and the soft buffer layer (2) are flame-bonded; the soft buffer layer (2) and the microfiber main body layer (3) are dot-coated; the microfiber main body layer (3) and the wear-resistant reinforcement layer (4) are TPU scraping film composite; the wear-resistant reinforcement layer (4) and the surface protection layer (5) are hot-pressed composite.

9. The soft and abrasion-resistant microfiber fabric according to claim 8, characterized in that, The dotted adhesive is water-based polyurethane adhesive, and the flame bonding is an adhesive-free bonding process.

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