Cotton is the most popular fabric used in human clothing and garment, and its joining process is still based on the traditional sewing method. In this study, a new approach to cotton fabric joining via UV-laser induced polymerisation was investigated, which involved preparation of a silane coupling agent (3-Aminopropyl) triethoxysilane (3-Aps) for surface modification of cotton fabric, and formulation and application of a silica-sol photosensitive resin as the filler. The developed resin consists of two other silanes, Silane A174 and KH560 so as to provide chemical bonds with the cellulose of cotton surface and the 3-Aps modified cotton. The results showed that the silica-sol resin not only produced self-polymerisation due to photothermal effect, but also joined with the fiber surfaces by chemical bonding, which enhanced the surface interaction with cotton fibers and obtained excellent mechanical properties. The heat accumulation at joint was detected in real-time using the infrared thermography, which ensured the fast drying and curing of the silica-sol containing resin. With 4 % silica-sol content in resin, the interfacial bonding was optimal for APS-Fabric, and the tensile force of the 2 mm joint reached 300 N exceeding the ultimate breaking strength of the cotton fabric itself. The fabric joint was demonstrated to withstand at least 20 washing cycles without cracking. This new fabric joining technique provides both strong bonding and sufficient flexibility in the joints, resulting in high strength and durable cotton fabric joining, which has a broad application prospect in the field of apparel.
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