Laundry Resistant, Double-Sided, Fluorine-Free, and Water Repellent Multi-Functional Processed Cloth and the Manufacturing Method Thereof

The present invention relates generally to a manufacturing method for processing cloth, and more particularly to a manufacturing method to obtain a laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth through a step during the dyeing procedure to immerse the base fabric after secondary washing into the acid-pickling and dye-fixing agent which is a mixture of dye-fixing agent and acetic acid, and a step during the setting procedure to immerse the base fabric into the water repellent mixture.

In recent years, along with the rapid development of material science, processed synthetic fibers can present various special functions, such as high elasticity, electrostatic protection, moisture and sweat absorption, UV protection, far infrared emission, electromagnetic wave resistance, negative ions, antibacterial and deodorizing effect. Such textiles with special properties can meet the various needs of different consumer groups. Therefore, many manufactures are investing in the research and development of functional textiles to develop textile products with more innovative functions.

Specifically, for the production of many functional textiles, specific materials are pulverized into nanoparticles, and then the nanoparticles are added into the original yarns to accomplish special functions of the textile. The new properties of the textile produced through this method can increase functionality while maintaining the quality and feel of the original textile.

Moreover, in order to enhance the efficiency and outcome of research and development of functional textiles, manufacturers are paying more attention to the functionality of products than appearance design. Through intensive research of material science to gain in-depth knowledge of the properties and applications of different materials, textile products with more functions can be developed by taking advantage of the special properties of different materials. Although the research and development market of functional textiles is enormous, to maximize its value, manufacturers need to make constant innovations, and conduct all-round explorations and trials in the aspects of materials, technologies, as well as market demands. With constant upgrading of technologies and constant change of the market, it is believed that functional textiles will be further developed and applied more widely.

With development of the times and evolution of technologies, cloth has become an essential part of daily life and is applied in various fields, such as clothing, furniture, vehicle decorations etc. The application range of cloth is very wide. However, the susceptibility of the conventional cloth to rain or other liquids may often cause inconvenience to life and affect the usability of the cloth. Therefore, it is of great importance to develop a processing method to produce breathable, waterproof or water repellent, and moisture penetrable cloth. With upgraded standard of living and pursuance of better quality of life, the demand for cloth is also increasing. Although the conventional types of cloth are soft and comfortable, their performance in wet environments is poor. The cloth may get damp, or cannot prevent seepage, or even cause a stuffy and uncomfortable feeling. Therefore, there is an urgent need for related textile manufacturers to develop a processing method to produce cloth with breathable, water repellent, and moisture penetrable properties.

Breathability is one of the most important properties of cloth. Cloth with good breathability can allow free penetration of air and vapor to maintain comfort of the body. Because of the close arrangement of fibers, the conventional cloth is not good in breathability, and may easily cause a stuffy feeling. Therefore, it is necessary to improve the breathability of cloth through technical means. Waterproof or water repellent property is an important aspect in modern cloth processing. Waterproof or water repellent cloth can have good resistance to the penetration of rain or other liquids, and the surface of the cloth can maintain dry, apart from protection to the cloth itself to extend the service life, such a property can also help maintain comfort of the user in wet environments. However, the prior-art processing method to accomplish the waterproof property often uses fluorine-containing agents, which have adverse influence to the environment and the health of people. Hence, there is an urgent need to develop a harmless processing method to accomplish the waterproof or water repellent property of cloth.

Therefore, it has become a common goal for textile-related technical researchers and manufacturers to develop a cloth processing method to accomplish breathable, waterproof or water repellent, moisture penetrable, as well as laundry resistant properties. Related manufacturers have leveraged the micro/nano technology of polymer materials to form a fine porous film on the surface of the cloth, which not only maintains the breathability of the cloth, but also prevents penetration of liquids. Meanwhile, by controlling the structure of the cloth and adding special functional agents, it is possible to accomplish the moisture penetrable property of the cloth, so that the wearer of the cloth can maintain dry and comfort in a wet environment. However, as the porous film technology only attaches a film material to one surface of the cloth, only the surface with attachment of the film has the aforementioned property. Moreover, as common film materials are mostly made of non-recyclable plastic raw materials, clothes made of such cloth cannot be recycled and utilized again, or may even cause pollution to the environment and high carbon discharge. The production of such materials requires considerable time and cost, and the fine porous film may come off easily and be damaged after repeated laundry. Therefore, the cloth is not laundry resistant. In addition, the film surface has a plastic feel when contacting the skin, and the appearance design of the cloth is relatively limited by the film. In view of this, it has become a significant topic among fiber textile processors to develop a processing method for effective and fast mass production of laundry resistant, fluorine-free, highly water repellent, moisture-proofing, and breathable cloth while maintaining environmental carbon reduction and the quality feel of the cloth, and greatly reducing the material and manufacturing costs.

Relying on the entrepreneurial spirit of the inventor in research and creation, and extensive knowledge as well as years of professional experience, the inventor of the present invention has conducted in-depth research to find solutions to the aforementioned technical problems. After repeated trials, the present invention is presented. The advantage of the production processes according to the present invention can truly improve the shortcomings of the prior-art processing methods.

The main object of the present invention is to provide an improved production method to produce multi-functional, fluorine-free, water repellent, breathable, and laundry resistant double-sided processed cloth.

In order to accomplish the above object, the laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth of the present invention comprises a base fabric layer and a rain-resistant water repellent composite layer, wherein, the base fabric layer is formed by weaving a plurality of weft units and a plurality of warp units with the units being neighboring and overlapping each other so that the base fabric layer has a first surface and a second surface relative to the first surface, a rain-resistant water repellent composite layer, disposed above the first surface and the second surface of the base fabric layer, wherein, the rain-resistant water repellent composite layer at least includes 30˜60 WT % water repellent agent and 40˜70 WT % rain-resistant agent, the water repellent agent at least includes 30˜85 WT % water repellent chemical and 15˜70 WT % cross-linking agent, the rain-resistant agent at least includes 20˜30 WT % paraffin emulsion, 1˜5 WT % fatty alcohol polyoxyethylene ether, and 65˜79 WT % water.

Another object of the present invention is to provide a method for manufacturing a laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth, which uses special manufacturing processes to enhance the water repellent and breathable effects of the cloth.

A further object of the present invention is to provide a laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth and the manufacturing method thereof to realize effective attachment of water repellent agent and rain-resistant agent on the cloth and fine texture of the cloth through improved manufacturing processes.

To accomplish the above objects, in the material preparation stage of the present invention of a laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth manufacturing method, firstly prepare a piece of base fabric. The base fabric is formed by weaving a plurality of weft units and a plurality of warp units with the units overlapping each other. This weaving method can produce stronger structure of the base fabric to endure more tension and pressure. Then, in the pre-processing step, the base fabric undergoes shrinking, loosening, semi-bleaching. presetting processes. These processes can make the fiber structure of the base fabric more homogeneous to enhance the subsequent dyeing and processing effects. The dyeing procedure is a key step in the whole manufacturing process. After the dyeing procedure, other procedures like washing, setting, secondary washing, and acid-pickling are conducted. It is to be noted that, in the acid-pickling and dye-fixing agent, dye-fixing chemical and acetic acid are added and mixed together in appropriate proportions, and the base fabric is immersed in the agent at temperatures of 75˜85° C., making sure the PH value is maintained in the range of 4.5˜5.5.

In the last post-processing step, the base fabric is dried and undergoes a setting procedure. During the setting process, 30˜60 WT % rain-resistant agent and 40˜70 WT % water repellent agent are mixed together, and then, the base fabric is soaked in the mixed solution. Then, a padding machine is used for padding to produce a double-sided fluorine-free water repellent base fabric. While maintaining comfort and softness of the cloth, such a processing method can enhance durability and waterproof performance of the cloth in wet environments.

For better understanding of the objects, technical means and advantages of the present invention, the present invention is described in detail below with respect to actual implementations. However, the scope of the present invention is not to be limited by the embodiment provided below. Without departing from the above technical concept of the invention, many other possible modifications and variations can be made based on common technical knowledge and means in the field. Such modifications and variations shall also be covered by the scope of the invention.

The present invention is a “laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth”.is a schematic view of the laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth according to the present invention, which comprises a base fabric layer () and a rain-resistant water repellent composite layer (), wherein, the base fabric layer () is formed by weaving a plurality of weft units and a plurality of warp units with the units being neighboring and overlapping each other, so that the base fabric layer () has a first surface () and a second surface () relative to the first surface (); a rain-resistant water repellent composite layer (), disposed above the first surface () and the second surface () of the base fabric layer (), wherein, the rain-resistant water repellent composite layer () at least includes 30˜60 WT % water repellent agent and 40˜70 WT % rain-resistant agent, the water repellent agent at least includes 30˜85 WT % water repellent chemical and 15˜70 WT % cross-linking agent, the rain-resistant agent at least includes 20˜30 WT % paraffin emulsion, 1˜5 WT % fatty alcohol polyoxyethylene ether, and 65˜79 WT % water. The laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth manufactured through the method disclosed in the present invention can have an overlapped structure with good water repellent, moisture-proofing, and breathable properties, and meanwhile, through the invention, the material and manufacturing costs can be greatly reduced.

is a flow diagram of the manufacturing method for the laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth according to the present invention. The manufacturing steps include:

SMaterial preparation stage: a base fabric is provided. The base fabric is formed by weaving a plurality of weft units and a plurality of warp units with the units being neighboring and overlapping each other. The plurality of weft units and the plurality of warp units can be made of polyester fiber, polyester cationic fiber, elastic fiber, or the combinations thereof.

SPre-processing: The base fabric undergoes shrinking, loosening, semi-bleaching, and presetting procedures.

SDyeing procedure: The base fabric undergoes dyeing, washing, setting, secondary washing, acid-pickling, and drying procedures. Characteristically, after secondary washing, the base fabric is immersed in an acid-pickling and dye-fixing agent at temperatures of 75˜85° C. The acid-pickling and dye-fixing agent is prepared by mixing dye-fixing agent and acetic acid at appropriate proportions, making sure the PH value is within the range of 4.5˜5.5. The acid-pickling procedure can remove the residual alkaline agent on the base fabric.

SPost-processing: After drying, the base fabric undergoes a setting procedure. Characteristically, in setting procedure, 30˜60 WT % rain-resistant agent and 40˜70 WT % water repellent agent are mixed. Specifically, the water repellent agent at least includes 30˜85 WT % water repellent chemical and 15˜70 WT % cross-linking agent, and the rain-resistant agent at least includes 20˜30 WT % paraffin emulsion, 1˜5 WT % fatty alcohol polyoxyethylene ether, and 65˜79 WT % water. Then, in the setting procedure, the base fabric is immersed in the mixed solution. After immersion, a padding machine is used for padding of the base fabric. Finally, double-sided fluorine-free water repellent multi-functional processed cloth is produced.

Through the aforementioned method for manufacturing laundry resistant, double-sided, fluorine-free, and water repellent multi-functional processed cloth, the cloth has laundry resistant, fluorine-free, highly water repellent, moisture-proofing, and breathable properties, and good durability and waterproof performance in wet environments. Meanwhile, due to better attachment of the agents, the cloth can have better laundry resistant, water repellent, moisture-proofing and breathable performances.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

In conclusion, the embodiment of the present invention can truly accomplish the anticipated effects. The specific structures disclosed in the present invention are not seen in other similar products and have not been made public before the patent application. Obviously, the present invention meets the regulations and requirements of the patent law. Therefore, a patent application is hereby submitted. Your examination and approval will be highly appreciated.