Precise Assembly of Highly Crystalline Colloidal Photonic Crystals inside the Polyester Yarns: A Spray Coating Synthesis for Breathable and Durable Fabrics with Saturated Structural Colors

Abstract It is a great challenge to prepare highly crystalline photonic crystal (PC)‐modified fabrics with saturated colors without sacrificing the wearing experience, such as breathability and softness, at the same time. Here, a spray coating process is developed to precisely assemble the colloidal PCs inside every yarn of the polyester (PET) fabric. High surface tension and high boiling point for the solvent of colloidal solution, as well as low twist angle, large weave cycles, and large tightness for the fabric substrate, are found to be favorable to the formation of high‐quality PC‐modified fabrics. In addition, the as‐prepared PC/PET fabrics have saturated and durable colors thanks to the highly crystalline PC structures and the polyacrylate adhesives. They also possess good softness and high breathability as the precise colloidal assembly in the yarn avoids the blocking of weaving holes and cracks.