During the production and use of woven cloth, static electricity is easily generated due to factors such as constant friction between fibers and a dry environment. This static electricity buildup not only causes the fabric to absorb dust and affect processing accuracy, but can also trigger spark discharges, posing a safety hazard in flammable and explosive environments. To reduce the risk of static electricity, coordinated improvements are needed across multiple dimensions, including fiber material selection, weave structure optimization, post-finishing process innovation, and production environment control. The following are specific technical paths and practical directions.
In terms of fiber material selection, the introduction of specialty fibers with antistatic properties is a fundamental innovation. Traditional synthetic fibers such as polyester and nylon lack polar groups in their molecular chains, resulting in poor hygroscopicity and high resistivity, making them prone to static electricity accumulation. Natural fibers such as cotton and linen, while highly hygroscopic, lack strength and abrasion resistance, making them inadequate for industrial fabric applications. Therefore, conductive fibers can be blended with conventional fibers to create static electricity dissipation channels. Conductive fibers include metal fibers (such as stainless steel fibers), carbon fibers, and organic conductive fibers (such as polyaniline and polypyrrole composite fibers). Metal fibers offer strong conductivity but suffer from poor flexibility and high cost. Carbon fibers offer both conductivity and flexibility, as well as excellent corrosion resistance. Organic conductive fibers can be produced through chemical polymerization or coating processes, are relatively inexpensive, and their conductivity can be controlled. Conductive fibers are evenly mixed into the warp or weft yarns at a specific ratio (usually 2%-5%). After weaving, a conductive network is formed, allowing static electricity to dissipate rapidly through corona discharge or conductive pathways, significantly reducing the surface resistance of the fabric.
Optimizing the weave structure is another key to reducing static electricity. By adjusting the warp and weft density, yarn arrangement, or introducing specialized weave structures, the area and frequency of interfiber friction can be reduced. For example, plain weaves have dense yarn interlacing points, resulting in frequent friction and a high risk of static electricity generation. Twill or satin weaves, however, have fewer interlacing points, resulting in less friction and a lower risk of static electricity accumulation. Alternatively, a two- or multi-layer composite structure can be designed, with the conductive fiber layer placed innermost and conventional fibers outermost. This ensures antistatic properties while maintaining the fabric's appearance and feel. For demanding applications, a grid-like inlay process can also be used, embedding conductive fibers into the fabric in a grid pattern at specific intervals (e.g., 5-10 mm) to form a uniform conductive network, further improving static dissipation efficiency.
Innovations in post-finishing processes offer flexible options for antistatic treatment. Chemical coating involves dispersing conductive materials (such as graphite, copper powder, and carbon nanotubes) in a film-forming agent such as polyurethane or acrylic acid. A conductive layer is then applied on the fabric surface via blade coating, spraying, or padding. This process requires controlling the coating thickness and uniformity to avoid affecting the fabric's flexibility and breathability. Physical adsorption utilizes the hydrophilic groups of surfactants (such as quaternary ammonium salts and polyoxyethylene ethers) to adsorb onto the fiber surface, forming a conductive water film and reducing surface resistance. This method is simple and low-cost, but suffers from poor washability and requires regular re-treatment. Furthermore, plasma treatment uses glow discharge to introduce polar groups (such as hydroxyl and carboxyl groups) onto the fiber surface, improving its hygroscopicity and conductivity. The treatment is long-lasting and suitable for the production of high-end antistatic fabrics.
Controlling the production environment is a crucial measure to combat static electricity. Static electricity accumulation is closely related to ambient humidity. When relative humidity exceeds 60%, the water film on the fiber surface thickens, increasing conductivity and effectively suppressing static electricity. Therefore, installing a humidification system in woven cloth production workshops to maintain humidity within a range of 55%-65% is a cost-effective and effective anti-static measure. Furthermore, controlling the temperature and cleanliness of the production workshop to reduce dust absorption can prevent static electricity from being exacerbated by friction caused by dust particles. Furthermore, using ionizing air guns or static eliminators during processes such as fabric winding and cutting can effectively neutralize surface charges on the fabric, preventing static electricity accumulation.
