Fabrication and characterization of polyester composite yarn with PVB/ZrC/Al₂O₃ coating

Abstract

As a functional textile, photothermal textile materials are receiving more and more attention. A composite yarn was prepared by coating polyvinyl butyral/zirconium carbide/alumina oxide on the surface of polyester yarn through a sizing coating method with the aim to provide a textile substrate with controlled photothermal efficiency. The Box–Behnken design combined with response surface analysis and regression method was used to study the effects of input variables (polyvinyl butyral, zirconium carbide and alumina oxide concentration) on the temperature of the fabric made of polyester/polyvinyl butyral/zirconium carbide/alumina oxide composite yarn under infrared light irradiation. It was found that the effect of polyvinyl butyral and zirconium carbide content on the fabric surface temperature was more significant than that of alumina oxide content. The established regression model could predict the response value (fabric temperature) precisely. The optimal conditions for preparing the polyester/polyvinyl butyral/zirconium carbide/alumina oxide composite yarn were obtained by response surface analysis: 5.9% polyvinyl butyral, 5% zirconium carbide and 0.5% alumina oxide. The structure and properties of the yarn prepared under the optimal conditions were characterized. The results showed zirconium carbide and alumina oxide deposited on surface coating without obvious deterioration of thermal stability and tensile strength. The near-infrared light absorption rate of the composite yarn reached 96.71% and its surface temperature reached 104.0°C after 180 s irradiation under an infrared lamp. The photothermal temperature can still reach 101.5°C after 20 cyclings. The excellent photothermal conversion capacity indicates the polyester/polyvinyl butyral/zirconium carbide/alumina oxide yarn can realize solar energy utilization and be applied in heat management textiles.