Composite fabric and preparation method therefor

Abstract

A composite fabric and a preparation method therefor. The fabric consists of a base fabric layer (1), an adhesive layer (2) and a plastic film layer (3), wherein the base fabric layer (1) is a fabric formed by interweaving warp and weft yarns having a denier of 50-300 D. The composite fabric is divided into a patterned part (100) and a flat part (200), and the thickness difference between the patterned part (100) and the flat part (200) does not exceed 20 μm. By optimally configuring the pattern part (100) and the flat part (200) of the base fabric layer (1), the contradiction between the aesthetics of the three-dimensional pattern effect and the durability of the final composite fabric product is effectively solved. By means of the optimal yarn count and fabric structure, the composite fabric has a uniform, fine and soft surface and a high-quality feel.

Description

A composite fabric and its preparation method Technical Field

[0001] This invention relates to a composite fabric and its preparation method, belonging to the field of composite material technology. Background Technology

[0002] As people's pace of life accelerates and their demands for quality of life continue to rise, organization and tidying have become not only essential daily chores but also enhance the quality and taste of life. Therefore, high-quality compression bags and other storage products are increasingly popular with consumers. Currently, most compression bags on the market are made of plastic film, which is easy to store and organize, but the plastic feel is too strong, resulting in a poor user experience. Furthermore, the limited strength of plastic means the products lack durability.

[0003] When choosing products, people consider not only their practicality and durability, but also their comfort and style. Embossed patterns offer a rich variety of styles; compared to two-dimensional printing, embossed patterns are more three-dimensional, possessing a sense of depth and a stronger visual impact. Currently, in textile finishing processes, embossing and burnout processes can achieve patterns with raised or recessed effects. Burnout processes, however, cause significant loss of fabric strength and are unsuitable for products with high durability requirements. Embossing, on the other hand, causes relatively less damage to the fabric's strength and can balance aesthetics and practicality. However, embossing inevitably results in unevenness on the fabric surface, increasing the processing difficulty of composite fabric bonding. The bonding strength of textile composite fabrics directly affects the product's durability and quality.

[0004] Currently, there is much research on improving the peel strength of composite fabrics. For example, patent CN116278280A describes a multifunctional composite fabric that uses a microporous membrane structure and hot-melt adhesive to achieve good peel strength between the fabric and the membrane. However, the airtightness of the microporous membrane structure has limitations and falls far short of the requirements for vacuum storage. Patent CN114714677A describes a composite outdoor fabric and its manufacturing process that uses plasma treatment on the film surface to eliminate impurities and improve its peel strength with the fabric. However, the patent does not mention its effect on improving peel strength, and plasma treatment currently lacks universal applicability. Summary of the Invention

[0005] The purpose of this invention is to solve the problems in the prior art and provide a composite fabric with high bonding strength and durability. This composite fabric has a distinct three-dimensional pattern and a delicate and soft touch.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A composite fabric comprises a base fabric layer, an adhesive layer, and a plastic film layer. The base fabric layer is characterized by being a fabric formed by the interweaving of warp and weft yarns with a denier of 50-300D. The surface of the composite fabric is divided into a patterned portion and a smooth portion, with the thickness difference between the patterned portion and the smooth portion not exceeding 20 μm. The warp and weft yarns of the base fabric can be interwoven in a plain weave, double plain weave, or square plain weave. The patterned portion is obtained through an embossing process, therefore the thickness of the patterned portion is less than the thickness of the smooth portion.

[0008] In this invention, the thickness of the flat portion of the base fabric layer is 0.16–0.37 mm, and the thickness of the patterned portion is 0.16–0.35 mm.

[0009] Preferably, the warp and weft yarns are made of a composite yarn of cationic polyester and ordinary polyester, with the proportion of cationic polyester in the composite yarn being 33-67%; furthermore, the warp and weft yarns may also be made of ordinary polyester yarn only.

[0010] Preferably, the warp and weft yarns have the same specifications, and the F number of the warp and weft yarns is 72 to 336F.

[0011] Preferably, the basis weight of the base fabric layer is 60–175 g / m². 2 The preferred composite fabric has a weight of 115–275 g / m². 2 .

[0012] Preferably, the plastic film layer is a PE film layer, a PA / PE composite film layer, or a PA / PE co-extruded film layer, and the basis weight of the plastic film layer is 30-80 g / m³. 2 .

[0013] A method for preparing the above-mentioned composite fabric, characterized by comprising the following steps:

[0014] S1. Using selected warp and weft yarns, interweave them on a water jet loom to form a grey fabric;

[0015] S2. The grease fabric is degreased, causticized, dyed, and set into colored fabric.

[0016] S3. The colored fabric is passed through a pattern roller and hot-pressed at high temperature to form a raised pattern, thus obtaining the base fabric layer;

[0017] S4. The base fabric layer is passed through a liquid roller that contacts the adhesive to apply the adhesive to the unembossed side of the base fabric layer. Then the base fabric layer and the plastic film are hot-pressed at high temperature to form a composite fabric.

[0018] S5. The composite fabric is rolled under tension to form a tube.

[0019] In step S2, the degreasing process involves using 2-3 g / L Na2CO3 and 4-5 g / L degreasing agent, treating at 90°C for 30 minutes, and rinsing once with 70°C hot water. Then, the fabric is subjected to a causticizing treatment using 4-7 g / L NaOH, rapidly heated to 100°C for 20 minutes, drained at 85°C, and rinsed twice with 80°C hot water.

[0020] In step S2, depending on the fabric requirements, only cationic polyester can be dyed to achieve a color-spun effect, or both cationic polyester and ordinary polyester can be dyed simultaneously to achieve a solid color effect.

[0021] In step S3, the hot pressing temperature of the pattern is 185-205℃, the processing speed is 12-15m / min, and the pressure is 1.5-2.5kg.

[0022] In step S4, the curing temperature of the base fabric layer and the plastic film layer during hot pressing is 100-110℃, the bonding and curing speed is 3-10m / min, and the pressure is 2-2.5kg.

[0023] In step S5, the rolling tension of the composite fabric is 15-30N, the rolling speed is 5-10m / min, and the roll needs to be left to stand for 8-12 hours under the conditions of temperature 25-40℃ and humidity 40-85% to ensure that the fabric and film have the best bonding strength.

[0024] Compared with the prior art, the present invention has the following advantages:

[0025] The composite fabric of this invention, through optimal settings of the patterned and flat portions of the base fabric layer, balances the conflicting demands of aesthetic appeal and durability in the final composite fabric product. With optimized yarn count and fabric structure, the composite fabric exhibits a uniform, delicate, soft surface and a high-quality feel.

[0026] This invention solves the peel strength problem in the bonding process between uneven fabrics and film by using a causticizing process, further improving the application of textured composite fabric as a composite film material for compression bags, and featuring high strength and durability. Attached Figure Description

[0027] Figure 1 is a cross-sectional structural diagram of the present invention;

[0028] Figure 2 is a schematic diagram of the compression bag made according to the present invention. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0030] As shown in Figures 1-2, a composite fabric is composed of a base fabric layer 1, an adhesive layer 2, and a plastic film layer 3. The base fabric layer 1 is a textured layer with interwoven warp and weft yarns. The surface of the composite fabric is divided into a patterned part 100 and a flat part 200. The thickness difference between the patterned part 100 and the flat part 200 does not exceed 20μm. The interweaving method of the warp and weft yarns of the base fabric can be a plain weave with single warp and single weft, a double plain weave, or a square plain weave.

[0031] Preferably, the thickness of the flat portion 200 is 0.16–0.37 mm, and the thickness of the patterned portion 100 is 0.16–0.35 mm. Maintaining an optimal thickness difference between the patterned portion 100 and the flat portion 200 aims to ensure both a certain three-dimensional feel to the fabric surface and relatively uniform high strength. When the thickness difference between the patterned portion and the flat portion exceeds 20 μm, the strength of the corresponding patterned portion will significantly decrease due to the influence of high temperatures, affecting the strength performance of the composite fabric.

[0032] Repeated experiments have shown that when the thickness difference between the patterned and smooth sections exceeds 20 μm, the strength value of the corresponding patterned section of the composite fabric decreases significantly, affecting the overall strength performance of the composite fabric. Under the same adhesive application rate, when the thickness difference between the patterned and smooth sections exceeds 20 μm, the adhesive application in the smooth section of the base fabric layer is insufficient, failing to meet the peel strength requirements of the composite fabric. Furthermore, when the thickness difference exceeds 20 μm, during high-temperature hot pressing of the patterned section, the yarn elongation is greater than that in the smooth section, resulting in larger pores in the patterned section and a smaller adhesive contact area. This leads to uneven adhesive application under the same adhesive application rate, resulting in lower peel strength in the patterned section of the composite fabric and ultimately lower peel strength for the entire composite fabric.

[0033] Furthermore, a fabric structure with a balanced warp and weft ratio is preferred, so that during the gluing process, the adhesive can be evenly distributed on the warp and weft yarns, resulting in a composite fabric with higher bonding strength.

[0034] The warp and weft yarns have the same specifications, with a denier of 50-300D and a fiber number of 72-336F. The selected yarn should not exceed 300D because if the yarn is too coarse, the gaps between the interlacing points of the base fabric and the outer fabric layer will be too large, making the fabric surface prone to glue seepage. The yarn should not be less than 50D because if the yarn is fine and the density is high, the fabric will be too thin, making it easy for the base fabric to show through in the composite fabric.

[0035] Preferably, the warp and weft yarns are composite yarns of cationic polyester and ordinary polyester, with cationic polyester accounting for 33% to 67% of the composite yarn. During subsequent printing and dyeing processes, the base fabric requires a causticizing process, i.e., surface hydrolysis treatment to roughen it. However, cationic polyester has a lower glass transition temperature than ordinary polyester, and its internal structure has larger pores, allowing hydroxide ions to more easily penetrate and etch and hydrolyze, resulting in more significant damage to the strength of the cationic polyester, thus affecting the processing of hot-pressed patterns. This invention satisfies the processing requirements of hot-pressed patterns by controlling the proportion of cationic polyester in the composite yarn. Simultaneously, this proportion allows for a very obvious two-tone difference in the fabric when dyeing cationic polyester alone, achieving a color-spun effect comparable to fabrics blended with colored staple fiber yarns, while simplifying the process and increasing durability.

[0036] Preferably, the basis weight of the base fabric layer is 60–175 g / m². 2 Furthermore, the weight of the composite fabric ranges from 115 to 275 g / m². 2 If the fabric weight is too low, the fabric tightness is too small, and the gaps between the filaments are too large. When hot pressing patterns, the filaments are easily slipped by external forces, causing the fabric to be punctured. In addition, glue seepage is likely to occur on the fabric surface, affecting the overall quality of the composite material. When the fabric weight is too high, although glue seepage will no longer occur, the hand feel will be noticeably stiff, and the user experience will be worse.

[0037] The plastic film layer is a PE film layer, a PA / PE composite film layer, or a PA / PE co-extruded film layer, and the basis weight of the plastic film layer is 30-80 g / m³. 2 If the plastic film is too thin, the composite fabric is prone to damage and holes; if the plastic film is too thick, the composite fabric will feel too stiff.

[0038] This invention provides a method for preparing composite fabrics, comprising the following steps:

[0039] S1. Using selected warp and weft yarns, interweave them on a water jet loom to form a grey fabric;

[0040] S2. The grease is degreased, causticized, dyed and set to form a colored fabric.

[0041] S3. The colored fabric is passed through a pattern roller and hot-pressed at high temperature to form a raised pattern, thus obtaining the base fabric layer;

[0042] S4. The base fabric layer is passed through a liquid roller that contacts the adhesive to apply the adhesive to the unembossed side of the base fabric layer. Then the base fabric layer and the plastic film are hot-pressed at high temperature to form a composite fabric.

[0043] S5. The composite fabric is rolled up under tension to form a tube. It needs to be left to stand for 8 to 12 hours under the conditions of temperature 25 to 40°C and humidity 40 to 85% to ensure that the fabric and film have the best adhesion.

[0044] In step S2, the degreasing process involves using 2-3 g / L Na2CO3 and 4-5 g / L degreasing agent, treating at 90°C for 30 minutes, and rinsing once with 70°C hot water. Then, the fabric is subjected to a causticizing treatment using 4-7 g / L NaOH, rapidly heated to 100°C for 20 minutes, drained at 85°C, and rinsed twice with 80°C hot water.

[0045] The surface of the filaments is relatively smooth. When the fabric and the film are bonded together using adhesive, the anchoring point area between the film and the fabric is small, and the friction between the individual filaments in the yarn is also small. This makes it easy for the filaments to slip, ultimately resulting in low peel strength between the film and the fabric. Although this invention improves the specific surface area of ​​the fabric by optimizing the design of the filament specifications and increasing the filament F number, thereby increasing the contact area between the fabric and the film during adhesive bonding, this method is significantly better than conventional monofilament bonding, but it still falls short of expectations.

[0046] Furthermore, this invention employs a causticizing treatment on the filaments, specifically a hydrolytic etching process to create a rough, uneven surface. This increases the contact area between the film and the fabric during adhesive application and, more importantly, enhances the anchoring area between the adhesive and the filament surface. However, causticizing causes hydrolysis of the filament surface, resulting in some damage to its strength. Furthermore, the causticizing process leads to the precipitation of hydrolysis products, causing significant problems in production. To address this issue, the temperature and time during causticizing are controlled, rapidly raising the temperature to a specific level while minimizing the time required for slow heating. This ensures the peel strength between the adhesive film and the fabric while minimizing the damage to strength caused by the causticizing process, thereby guaranteeing the strength of subsequent hot-pressing patterns. The causticized small-molecule polymers can dissolve and disperse well in water in colloidal form under high-temperature alkaline conditions. To prevent these small-molecule polymers from precipitating out of the water, this invention employs high-temperature drainage without neutralization, thus avoiding the re-adhesion of small-molecule polymers onto the fabric surface and the formation of dark spots.

[0047] In step S3, the hot-pressing temperature of the pattern is 185–205℃, the processing speed is 12–15 m / min, and the pressure is 1.5–2.5 kg. By balancing the relationship between the hot-pressing temperature, speed, and pressure, a certain thickness difference in the textured pattern is formed on the fabric. The fabric is heated at a temperature approximately 90℃ above the glass transition temperature and approximately 235–240℃ below the crystal melting temperature. This primarily acts on the amorphous regions of the fibers, causing internal rotational motion of the molecular chain segments, adjusting the molecular conformation, eliminating local internal stress in the fibers, and increasing the crystalline regions within the fiber molecules. The resulting textured pattern is irreversible, thus its effect is relatively stable and permanent. Multiple experiments have shown that this thickness difference does not significantly reduce the mechanical properties of the fabric, ensuring its strength while providing a very exquisite three-dimensional textured visual effect.

[0048] In step S4, the curing temperature of the base fabric layer and the plastic film layer during hot pressing is 100-110℃, the bonding and curing speed is 3-10m / min, and the pressure is 2-2.5kg.

[0049] When bonding the aforementioned patterned base fabric, the uneven surface can cause localized areas where adhesive cannot be applied during dispensing. Therefore, when the pressure is too low and the machine speed is too high, the base fabric cannot achieve proper dispensing and bonding, resulting in weak peel strength. Conversely, when the pressure is too high and the machine speed is too slow, the base fabric and film are subjected to prolonged compression. Although sufficient bonding occurs under these conditions, the original pattern is prone to deformation, leading to unclear pattern definition. To reduce the interaction between machine speed and pressure, this invention optimizes the bonding and curing speed and pressure to achieve the desired peel strength and base fabric pattern.

[0050] The embossed base fabric layer is bonded to the plastic film with adhesive. The unembossed side of the base fabric layer and the film are then pressed together by a liquid roller with adhesive attached at high temperature to form a composite fabric.

[0051] In one embodiment, changing the fabric structure, the ratio of cation and polyester, the warp and weft yarn count, the fabric weight, the thickness of the fabric and the pattern, the weight of the plastic film, and the weight of the adhesive can give the composite fabric different styles.

[0052] The composite fabric of the present invention will be further described below through specific embodiments and comparative examples.

[0053] The tissue parameters of Examples 1-9 (Actual 1-9) and Comparative Examples 1-6 (Comparative 1-6) are shown in Table 1.

[0054] Table 1: The unit of weight is g / m³ 2 The proportion of cationic polyester in colored fabrics is the mass percentage of cationic polyester.

[0055] The preparation methods of Examples 1-9 and Comparative Examples 1-6 are as follows.

[0056] Example 1:

[0057] A greige fabric was woven on a water-jet loom with a warp and weft count of 150D / 144F and a 33% cation-polyester ratio. The fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 5g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. The cation-polyester was dyed with cationic dyes to obtain a fabric with a basis weight of 115g / m². 2 A 0.246mm thick yarn-dyed fabric is passed through a patterned roller and hot-pressed at 190℃, 13m / min, and 2kg to form a 0.24mm thick pattern, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.006mm. The base fabric layer is then bonded with 10g / m² adhesive. 2 The adhesive roller with liquid flow, with 60g / m 2 The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 20N and a rolling speed of 8m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0058] Example 2:

[0059] Yarn with a warp and weft count of 75D / 72F and a 50% cation-polyester ratio was woven into a grey fabric on a water-jet loom using a plain weave structure. The grey fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 4g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. The cation-polyester was dyed with cationic dyes to obtain a fabric with a basis weight of 80g / m². 2 A 0.246mm thick yarn-dyed fabric is passed through a patterned roller and hot-pressed at 190℃, a processing speed of 13m / min, and a pressure of 2kg to form a 0.24mm thick pattern, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.006mm. The base fabric layer is then subjected to contact bonding with 5g / m²... 2 The adhesive roller with liquid content of 30g / m 2The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 15N and a rolling speed of 10m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0060] Example 3:

[0061] Yarn with a warp and weft count of 300D / 336F and a 67% cation-polyester content was woven into a grey fabric on a water-jet loom using a plain weave structure. The grey fabric was then treated with 3g / L Na2CO3 and 5g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 7g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. The cation-polyester was dyed with cationic dyes to obtain a weight of 153g / m². 2 A 0.36mm thick yarn-dyed fabric is passed through a patterned roller and hot-pressed at 190℃, a processing speed of 12m / min, and a pressure of 2.2kg to form a pattern with a thickness of 0.348mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.012mm. The base fabric layer is then subjected to contact bonding with 15g / m²... 2 The adhesive roller with liquid content of 30g / m 2 The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 25N and a rolling speed of 6m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0062] Example 4:

[0063] A greige fabric was woven on a water-jet loom with a warp and weft count of 150D / 144F and a 50% cationic polyester content, using a plain weave structure. The fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 5g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. Simultaneously, cationic and ordinary polyester were dyed to obtain a fabric with a basis weight of 115g / m². 2 A solid-color fabric with a thickness of 0.246mm is used. The fabric is then passed through a patterned roller, hot-pressed at 190℃, at a processing speed of 13m / min, and with a pressure of 2kg, to form a pattern with a thickness of 0.24mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.006mm. The base fabric layer is then coated with a 20g / m² adhesive. 2 The adhesive roller with liquid flow, with 60g / m 2The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 20N and a rolling speed of 8m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0064] Example 5:

[0065] A greige fabric was woven on a water-jet loom with a warp and weft count of 300D / 336F and a 50% cationic polyester content, using a plain weave structure. The fabric was then treated with 3g / L Na2CO3 and 5g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 7g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. Simultaneously, cationic and ordinary polyester were dyed to obtain a fabric with a basis weight of 153g / m². 2 A solid-color fabric with a thickness of 0.37mm is used. The fabric is then passed through a patterned roller, hot-pressed at 205℃, at a processing speed of 12m / min, and with a pressure of 2.5kg, to form a pattern with a thickness of 0.35mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.020mm. The base fabric layer is then subjected to contact bonding with 18g / m²... 2 The adhesive roller applies the adhesive to the base fabric, then the base fabric layer and 60g / m 2 The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 25N and a rolling speed of 6m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0066] Example 6:

[0067] A greige fabric was woven on a water-jet loom with a warp and weft count of 150D / 144F and a 50% cationic polyester content, using a plain weave structure. The fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 5g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. Simultaneously, cationic and ordinary polyester were dyed to obtain a fabric with a basis weight of 115g / m². 2 A solid-color fabric with a thickness of 0.246mm is used. The fabric is then passed through a patterned roller, hot-pressed at 190℃, at a processing speed of 13m / min, and with a pressure of 2kg, to form a pattern with a thickness of 0.24mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0.006mm. The base fabric layer is then coated with a 10g / m² adhesive. 2The adhesive roller applies the adhesive to the base fabric, then the base fabric layer and 80g / m 2 The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 20N and a rolling speed of 8m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0068] Example 7:

[0069] A greige fabric was woven on a water-jet loom with a warp and weft count of 300D / 336F and a 67% cationic polyester content. The fabric was then treated with 3g / L Na2CO3 and 5g / L degreasing agent at 90℃ for 30 minutes, rinsed once with 70℃ hot water, and subsequently treated with 7g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with 80℃ hot water. Simultaneously, cationic and ordinary polyester were dyed to obtain a solid-color fabric with a weight of 149g / m2 and a thickness of 0.34mm. The solid-color fabric was then passed through a pattern roller and hot-pressed at 190℃, a speed of 12m / min, and a pressure of 2.1kJ / m2. g, forming a pattern with a thickness of 0.328mm to obtain a base fabric layer, wherein the thickness difference between the flat part and the patterned part is 0.012mm; the base fabric layer is passed through a liquid roller with 15g / m2 of glue applied to it and hot-pressed with a plastic film of 30g / m2 at high temperature to form a composite fabric; the composite fabric is rolled into a tube at a rolling tension of 25N and a rolling speed of 6m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0070] Example 8:

[0071] Ordinary polyester filament with a warp and weft count of 50D / 72F was woven into a grey fabric on a water-jet loom using a plain weave structure. The grey fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 4g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. Simultaneously, the ordinary polyester was dyed to obtain a fabric with a basis weight of 60g / m². 2 A solid-color fabric with a thickness of 0.195mm is used. The fabric is then passed through a patterned roller, hot-pressed at 185℃, at a processing speed of 15m / min, and with a pressure of 1.5kg, to form a pattern with a thickness of 0.195mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0mm. The base fabric layer is then coated with a 15g / m² adhesive. 2 The adhesive roller with liquid flow, with 60g / m 2The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 15N and a rolling speed of 10m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0072] Example 9:

[0073] Ordinary polyester filament with a warp and weft count of 50D / 72F was woven into a grey fabric on a water-jet loom using a plain weave structure. The grey fabric was then treated with 2g / L Na2CO3 and 4g / L degreasing agent at 90℃ for 30 minutes, rinsed once with hot water at 70℃, and subsequently treated with 4g / L NaOH at 100℃ for 20 minutes. The fabric was drained at 85℃ and rinsed twice with hot water at 80℃. Simultaneously, the ordinary polyester was dyed to obtain a fabric with a basis weight of 60g / m². 2 A solid-color fabric with a thickness of 0.160mm is used. The fabric is then passed through a patterned roller, hot-pressed at 185℃, at a processing speed of 15m / min, and with a pressure of 1.5kg, to form a pattern with a thickness of 0.160mm, resulting in a base fabric layer. The thickness difference between the flat and patterned portions is 0mm. The base fabric layer is then coated with a 10g / m² adhesive. 2 The adhesive roller with liquid content of 40g / m 2 The plastic film is hot-pressed at high temperature to form a composite fabric; the composite fabric is rolled into a tube with a rolling tension of 15N and a rolling speed of 10m / min, and left to stand for 10 hours under the conditions of 30℃ and 75% humidity to ensure that the fabric and film have the best bonding strength.

[0074] Comparative Example 1:

[0075] Comparative Example 1 was carried out in accordance with Example 1, except that the embossing pressure was changed to 2.6 kg.

[0076] Comparative Example 2:

[0077] Comparative Example 2 was carried out in accordance with Example 1, except that the amount of NaOH used in the causticizing process was changed to 8 g / L.

[0078] Comparative Example 3:

[0079] Comparative Example 3 was carried out in accordance with Example 1, except that the amount of NaOH used in the causticizing process was changed to 3 g / L.

[0080] Comparative Examples 4-5:

[0081] Comparative Examples 4 and 5 were prepared according to the preparation method of Example 3.

[0082] Comparative Example 6:

[0083] Comparative Example 6 was prepared according to the method in Example 2.

[0084] Tests were conducted on Examples 1-9 and Comparative Examples 1-6. The tensile breaking strength of the composite fabric was tested according to the standard GB / T 1040-1992, Test Method for Tensile Properties of Plastics. The peel strength was tested according to the Method A method for composite films in the standard GB / T 8808-1988, Peel Test Method for Flexible Composite Plastic Materials. The puncture strength was tested according to the standard GB / T 37841-2019, Test Method for Puncture Resistance of Plastic Films and Sheets. The test results are shown in Table 2.

[0085] Table 2:

[0086] The test results show that: Comparative Example 1, with its excessive embossing, resulted in reduced strength and puncture resistance in the composite fabric; Comparative Example 2, by increasing the amount of NaOH used in the causticizing process, caused excessive fiber dissolution, leading to reduced strength and easy peeling of the composite fabric; Comparative Example 3, by reducing the amount of NaOH used in the causticizing process, reduced the binding sites between the fibers and dyes, resulting in easy separation between the fabric and the film; Comparative Example 4, by altering the structure of the base fabric, caused easy peeling between the film and the base fabric in the composite fabric; Comparative Example 5, with its coarse yarn count, although showing a slight improvement in physical properties, resulted in a stiff feel, rough fabric texture, severe "glue seepage," a shiny fabric surface, and a strong plastic feel; Comparative Example 6, with its fine yarn count, resulted in a very thin composite fabric, with a significant decrease in all physical performance indicators and "background showing" on the fabric surface.

[0087] The composite fabric obtained by this invention has excellent peel strength (peel strength > 6N) and excellent puncture resistance (puncture strength > 25N), which is more robust and durable than conventional films (puncture force about 10-15N). The fabric and film have good adhesion strength. The composite fabric has a uniform and delicate surface, a comfortable feel, no plastic feel, and a high-quality feel, making it suitable for application and promotion in home furnishing products.

[0088] Examples 1-9 are all feasible implementation schemes within the technical requirements of this invention.

[0089] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0090] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A composite fabric, comprising a base fabric layer, an adhesive layer, and a plastic film layer, characterized in that... The base fabric layer is a fabric formed by interlacing warp and weft yarns of 50-300D. The surface of the composite fabric is divided into a patterned part and a flat part. The thickness difference between the patterned part and the flat part does not exceed 20μm. The warp and weft yarns of the base fabric are interlaced in plain weave, double plain weave, or square plain weave.

2. The composite fabric according to claim 1, characterized in that... The thickness of the flat portion is 0.16–0.37 mm, and the thickness of the patterned portion is 0.16–0.35 mm.

3. The composite fabric according to claim 1, characterized in that... The warp and weft yarns are made of cationic polyester and ordinary polyester composite yarn, with cationic polyester accounting for 33-67% of the composite yarn.

4. The composite fabric according to claim 1, characterized in that... The warp and weft yarns are made of ordinary polyester filament.

5. A composite fabric according to claim 1, characterized in that... The warp and weft yarns have the same specifications, and the F number of the warp and weft yarns is 72F to 336F.

6. A composite fabric according to claim 1, characterized in that... The base fabric layer has a basis weight of 60–175 g / m². 2 .

7. A composite fabric according to claim 6, characterized in that... The composite fabric has a weight of 115–275 g / m². 2 .

8. A composite fabric according to claim 1, characterized in that... The plastic film layer is a PE film layer, a PA / PE composite film layer, or a PA / PE co-extruded film layer, and the average basis weight of the plastic film layer is 30-80 g / m³. 2 .

9. A method for preparing the composite fabric according to any one of claims 1-8, characterized in that... Includes the following steps: S1. The selected warp and weft yarns are interwoven on a water jet loom to form a grey fabric. S2. The grease fabric is degreased, causticized, dyed, and set into colored fabric. S3. The colored fabric is passed through a pattern roller and hot-pressed at high temperature to form a raised pattern, thus obtaining the base fabric layer; S4. The base fabric layer is passed through a liquid roller that contacts the adhesive to apply the adhesive to the unembossed side of the base fabric layer. Then the base fabric layer and the plastic film are hot-pressed at high temperature to form a composite fabric. S5. The composite fabric is rolled up under tension to form a tube.

10. The method for preparing a composite fabric according to claim 9, characterized in that... In step S2, the degreasing process involves using 2-3 g / L Na2CO3 and 4-5 g / L degreasing agent, treating at 90°C for 30 minutes, and rinsing once with 70°C hot water. Then, the fabric undergoes a causticizing treatment using 4-7 g / L NaOH, rapidly heating to 100°C for 20 minutes, draining at 85°C, and rinsing twice with 80°C hot water.

11. The method for preparing a composite fabric according to claim 9, characterized in that... In step S3, the hot pressing temperature of the pattern is 185-205℃, the processing speed is 12-15m / min, and the pressure is 1.5-2.5kg; in step S4, the curing temperature of the base fabric layer and the plastic film layer during hot pressing is 100-110℃, the bonding and curing processing speed is 3-10m / min, and the pressure is 2-2.5kg; in step S5, the rolling tension of the composite fabric is 15-30N, the rolling speed is 5-10m / min, and the tubular material needs to be left to stand for 8-12 hours under the conditions of temperature 25-40℃ and humidity 40-85%.

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