Cotton-mullite wool air layer textile material

Abstract

The invention provides a cotton-cotton wool air layer textile material which comprises an outer layer, a middle layer and an inner layer, the middle layer is a spandex layer, the outer layer is a modal cotton blending layer, the inner layer is an acrylic fiber wool blending layer, and the air layer textile material is processed and manufactured through the following procedures of S1, spinning; s2, yarn dyeing; s3, weaving; s4, shaping for the first time; s5, galling is conducted; s6, wool washing; s7, carrying out secondary shaping; s8, performing loose drying; and the like. Through unique material combination, precise process design and the synergistic effect of a plurality of key steps, the industrial problem that the composite functional fabric is difficult to balance in the aspects of moisture absorption, heating, breathability, warm keeping, hair slip, pilling, softness, dimensional stability and the like is solved.

Description

Technical Field

[0001] This invention relates to the field of clothing technology, specifically to a cotton-moisture wool air-layer textile material. Background Technology

[0002] Air layer fabric is a functional fabric with an air sandwich structure that is widely used in clothing, sports equipment, home decorations and other fields. It mainly serves to keep warm. Through structural design, it adopts a three-layer fabric structure of inner, middle and outer layers, thereby forming an air sandwich in the fabric to achieve the effect of keeping warm. In woven fabrics, a double-layer structure can be used, and a system of warp or weft yarns can be added between the warp and weft yarns of the outer and inner layers to form a sandwich structure of inner, middle and outer layers. The middle layer uses a filling yarn with good fluffiness and elasticity to form a static air layer to achieve the effect of keeping warm. However, the existing air layer fabrics have the following defects: (1) In order to pursue the effect of keeping warm, the overall fluffiness of the material is low and the breathability is poor; (2) The skin-friendly, moisture-absorbing and heat-generating effects are poor, and it is impossible to achieve the effect of keeping warm on one side and being breathable on the other side, keeping warm when cold and sweating when hot; (3) The fabric has weak anti-pilling and anti-shedding properties. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention proposes a cotton-moisture wool air-layer textile material. Through a unique material combination, precise process design, and the synergistic effect of multiple key steps, it solves the industry problem of balancing the performance of composite functional fabrics in terms of moisture absorption and heat generation, breathability and warmth retention, shedding and pilling, softness and dimensional stability.

[0004] To achieve the above technical solution, the present invention provides a cotton-modal-wool air-layer textile material, comprising: an outer layer, a middle layer, and an inner layer, wherein the middle layer is an spandex layer, the outer layer is a modal-cotton blend layer, and the inner layer is an acrylic-wool blend layer. The air-layer textile material is manufactured through the following processes: S1. Spinning: Viscose, acrylic, and wool are spun together to obtain the inner layer yarn; Modal and cotton are spun together to obtain the outer layer yarn. S2. Yarn Dyeing: Both the inner and outer yarns are dyed using cone dyeing after spinning. For the inner yarn, after dyeing, glycerol and polyurethane are added to the dyeing vat to treat the yarn. The formula and process are as follows: glycerol 10-20 g / L; polyurethane 5-10 g / L; acetic acid 0.1-0.3 g / L, controlled temperature 60-80℃, time 15-20 min. After treatment, the water is drained, and the cone yarn is dried using an RF dryer. Simultaneously, the inner yarn undergoes a cross-linking reaction with the glycerol and polyurethane. S3. Fabric weaving: The air layer fabric is woven into the designed fabric structure using a circular knitting weft knitting machine. The inner layer is a blend of viscose, acrylic, and wool yarns, the outer layer is a blend of modal and cotton yarns, and the middle layer is connected with spandex. Bare spandex is added during the weaving process to increase elasticity. S4. First setting: After the fabric is impregnated with a napping agent on the setting machine, it is then set and dried by hot air stretching, and 10-30g / L of napping agent and 1-3g / L of penetrant are added. The machine speed is 40-60m / min and the temperature is 130-160℃. S5. Nailing: Nail the inner layer of the fabric. Use a 6-box 48-roll napping machine to nap three times. After napping, iron the fabric and then trim the nap. S6. Washing: The napped fabric is treated with a washing machine to remove lint and dust at a temperature of 30-50℃ and a speed of 20-30m / min. S7. Second setting: After washing and drying, the fabric is impregnated with softener on a setting machine, then set and dried by hot air stretching, and 10-30g / L of hydrophilic softener and 1-3g / L of penetrant are added. The pH is adjusted to 5-7 with acetic acid, and the machine speed is controlled at 40-60m / min and the temperature is 130-160℃. S8. Loose drying: After the velvet enters the flat net loose drying machine, it is conveyed forward in a wave-like shape. The temperature is 130-135℃, the overfeed is 18-22%, and the speed is 15-16 meters / minute. The fabric is patted to make it feel fluffy, and stress is released at the same time to improve shrinkage.

[0005] In the above technical solution, by adopting a structural design with an intermediate layer of spandex, an outer layer of modal cotton blend, and an inner layer of acrylic wool blend, the effect of being both warm and breathable is achieved, allowing for warmth in cold weather and perspiration wicking in hot weather.

[0006] Preferably, in step S1, the twist of the outer layer yarn is controlled to be 85-100 twists / 10cm, and the twist of the inner layer yarn is controlled to be 95-115 twists / 10cm. Using a relatively low twist (85-100 twists / 10cm) for the outer layer yarn helps maintain the soft feel of modal and cotton; using a higher twist (95-115 twists / 10cm) for the inner layer yarn enhances yarn strength, helps hold the fibers during napping, reduces excessive shedding, and makes the resulting pile more robust. This differentiated design balances the fabric's appearance and intrinsic quality.

[0007] Preferably, in step S5, the first napping roller speed is 600-800 rpm, the fabric speed is 8-12 m / min, and the tension is 10-13 N; the second napping roller speed is 800-1000 rpm, the fabric speed is 12-16 m / min, and the tension is 13-16 N; the third napping roller speed is 1000-1200 rpm, the fabric speed is 16-20 m / min, and the tension is 16-19 N. By gradually increasing the roller speed, fabric speed, and tension, the purpose is to gradually increase the napping depth, making the nap even, neat, and dense, and preventing excessive damage to the yarn. This progressive process of increasing roller speed, fabric speed, and tension in three stages of napping, from light to heavy and gradually deeper, can evenly and controllably raise the nap, avoiding damage to the base fabric or uneven nap caused by excessive intensity at one time.

[0008] Preferably, in step S5, the temperature of the heat-pressing roller is 80°C and the fabric speed is 20m / min.

[0009] Preferably, in step S5, after ironing, the hair is sheared at a speed of 800 rpm and a fabric speed of 8 m / min.

[0010] Preferably, in step S2, the formulation process is as follows: glycerol 15g / L; polyurethane 8g / L; acetic acid 0.2g / L, with the temperature controlled at 70℃ and the time at 20min.

[0011] Preferably, in step S4, 20 g / L of a hair-raising agent and 2 g / L of a penetrant are added, the machine speed is 50 m / min, and the temperature is 150°C.

[0012] Preferably, in step S7, 20 g / L of hair-raising agent and 2 g / L of penetrant are added, the pH is adjusted to 6 with acetic acid, the vehicle speed is controlled at 50 m / min, and the temperature is 150°C.

[0013] The beneficial effects of the cotton-wool air-layer textile material provided by this invention are as follows: (1) This invention adopts a three-layer structure of “outer-middle-inner” to achieve functional integration. The outer layer (modal cotton) provides a skin-friendly, moisture-wicking, and breathable wearing feel, and ensures the external quality of the fabric. The middle layer (spandex) serves as a connecting layer, providing the lateral and longitudinal elasticity required by the fabric, ensuring freedom of movement and a close fit. The inner layer (acrylic / wool blend, napped): acrylic gives it a fluffy feel and a wool-like style, wool provides natural warmth, and the napped layer effectively traps air, greatly improving the warmth and providing a soft skin feel.

[0014] (2) This invention solves the industry problem of balancing the performance of composite functional fabrics in terms of moisture absorption and heat generation, breathability and warmth retention, shedding and pilling, softness and dimensional stability through unique material combination, precise process design, and the synergistic effect of multiple key steps. Furthermore, through innovative spinning processes and yarn treatment, the moisture absorption and conductivity of the yarn are improved, enhancing the fabric's moisture absorption and heat generation functions and breathability, while keeping the inner skin-contact surface drier. A special process is used during the napping of the fabric to make the surface pile short, dense, fluffy, delicate, and neat, improving the heat retention performance while mitigating the shedding and pilling problems caused by ordinary napping.

[0015] (3) This invention innovatively designs a full-chain solution for the special combination of "modal / cotton + spandex + acrylic / wool" in the form of "yarn pretreatment enhancement (S2) → structured weaving (S3) → setting and napping aid (S4) → fine napping finishing (S5) → stress release (S8)". In particular, the inner yarn is reinforced during the dyeing stage to cope with subsequent napping, and the loose drying process is used in the final process to specifically solve the shrinkage problem of elastic napped fabric.

[0016] (4) The present invention utilizes a special treatment in step S2, yarn dyeing: after dyeing, the inner layer yarn is treated with glycerol and polyurethane to allow the yarn to absorb and crosslink. The strong water absorption capacity of glycerol further enhances the yarn's hygroscopicity. Furthermore, the crosslinking film-forming reaction of polyurethane under subsequent radio frequency drying conditions forms a flexible protective film on the fiber surface, significantly enhancing the strength of the inner layer yarn and reducing fiber breakage and shedding during the subsequent vigorous napping process. This effectively improves the fabric's anti-pilling and anti-shedding properties while achieving a full, fluffy pile. Step S5 involves staged napping and finishing: a combined process of "three-stage napping → calendering → shearing." The three-stage napping gradually strengthens the nap, ensuring even and sufficient raising with minimal damage to the base fabric; calendering orients and straightens the nap, imparting luster; shearing ensures consistent nap length and a smooth, high-end appearance. This process combination is crucial for obtaining a high-quality, consistent nap. Step S8, loose drying: After final shaping, wave-like conveying and patting drying are added, which can fully release the internal stress accumulated in the fabric during weaving and napping, greatly improve the dimensional stability of the finished product (reduce shrinkage rate), and make the fabric feel more fluffy and soft. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the cotton-wool air layer textile material in this invention.

[0018] Figure 2 This is a process flow diagram of the present invention.

[0019] In the diagram: 1. Outer layer; 2. Middle layer; 3. Inner layer. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

[0021] Example 1: A cotton-moist wool air-layer textile material.

[0022] Reference Figures 1 to 2 As shown, a cotton-modal-wool air-layer textile material includes: an outer layer 1, a middle layer 2, and an inner layer 3. The middle layer 2 is an spandex layer, the outer layer 1 is a modal-cotton blend layer, and the inner layer 3 is an acrylic-wool blend layer. The outer layer 1 (modal-cotton blend layer) is soft and comfortable; the middle layer 2 (spandex layer) offers excellent elasticity and coverage; and the inner layer 3 (acrylic-wool blend layer) is soft, warm, and cozy. This three-layer structure integrates functions: the outer layer (modal cotton) provides a skin-friendly, moisture-wicking, and breathable feel while ensuring the fabric's external quality; the middle layer (spandex) acts as a connecting layer, providing the necessary lateral and longitudinal elasticity to ensure freedom of movement and a close fit; and the inner layer (acrylic / wool blend, napped) combines acrylic for a fluffy feel and wool-like texture, wool for natural warmth, and the napped layer effectively traps air, greatly enhancing warmth and providing a soft feel against the skin. This invention achieves the effect of being both warm and breathable by using a structural design with an intermediate spandex layer, an outer modal cotton blend layer, and an inner acrylic wool blend layer. It can keep you warm when it's cold and allow you to sweat when it's hot.

[0023] The outer layer 1, the middle layer 2, and the inner layer 3 are combined using the following method: S1. Spinning: Viscose, acrylic, and wool are spun using a compact spinning method to obtain the inner layer yarn; Modal and cotton are spun using the same method to obtain the outer layer yarn. The twist of the outer layer yarn is controlled at 95 twists / 10cm, and the twist of the inner layer yarn is controlled at 105 twists / 10cm. The relatively low twist of the outer layer yarn (95 twists / 10cm) helps maintain the soft hand feel of Modal and cotton; the higher twist of the inner layer yarn (105 twists / 10cm) enhances the yarn strength, helps hold the fibers during napping, reduces excessive shedding, and makes the resulting pile more robust. This differentiated design takes into account both the fabric's appearance and intrinsic quality. Compact spinning combines the ply structure of Siro spinning with the tightly packed fiber arrangement of compact spinning, resulting in high fiber parallelism, neat surface fiber arrangement, good yarn evenness, a soft and crisp hand feel, significantly reduced risk of pilling and fuzzing, reduced fuzz, and improved fabric smoothness. The twist of the outer yarn is controlled at 95 twists / 10cm, and the twist of the inner yarn is controlled at 105 twists / 10cm. The higher twist can create larger gaps between the yarns, allowing for smoother air circulation and better breathability. Sweat can be quickly wicked away, avoiding a stuffy feeling. At the same time, the increased yarn tightness reduces the water retention capacity, allowing the absorbed sweat to be quickly transferred to the outer layer, thus keeping the inner layer dry.

[0024] S2. Yarn Dyeing: Both the inner and outer yarns are dyed using cone dyeing after spinning. For the inner yarn, glycerol and polyurethane are added to the dye bath after dyeing to treat the yarn. The formula is as follows: glycerol 15g / L; polyurethane 8g / L; acetic acid 0.2g / L, controlled at 70℃ for 20 minutes. After treatment, the water is drained, and the cone yarn is then dried using an RF dryer. Simultaneously, the inner yarn undergoes a cross-linking reaction with the glycerol and polyurethane. The strong water absorption capacity of glycerol further improves the yarn's hygroscopicity, and the subsequent cross-linking film-forming reaction of polyurethane under RF drying conditions improves wash resistance and mitigates the pilling and shedding problems common in ordinary napped fabrics.

[0025] S3. Fabric weaving: The air layer fabric is woven into the designed fabric structure using a circular knitting weft knitting machine. The inner layer is a blend of viscose, acrylic, and wool yarns, the outer layer is a blend of modal and cotton yarns, and the middle layer is connected with spandex. Bare spandex is added during the weaving process to increase elasticity.

[0026] S4. First setting: After the fabric is impregnated with a napping agent on the setting machine, it is then set and dried by hot air stretching. 20g / L of napping agent and 2g / L of penetrant are added. The machine speed is 50m / min and the temperature is 150℃.

[0027] S5. Nailing: The inner layer of the fabric is napped using a 6-box, 48-roll napping machine with three napping passes. After napping, the fabric is calendered at 80℃ and the fabric speed is 20m / min. After calendering, the nap is sheared at 800rpm and the fabric speed is 8m / min. Specifically, the first napping roller speed is 600-800rpm, the fabric speed is 8-12m / min, and the tension is 10-13N; the second napping roller speed is 800-1000rpm, the fabric speed is 12-16m / min, and the tension is 13-16N; the third napping roller speed is 1000-1200rpm, the fabric speed is 16-20m / min, and the tension is 16-19N. By gradually increasing the roller speed, fabric speed, and tension, the aim is to gradually increase the napping depth, making the nap even, neat, and dense, while preventing excessive damage to the yarn. The progressive process of three-stage napping—increasing rotation speed, increasing fabric speed, and increasing tension—allows for even and controllable napping, preventing damage to the base fabric or uneven nap due to excessive intensity at one time.

[0028] S6. Washing: The napped fabric is treated with a washing machine to remove lint and dust at a temperature of 30-50℃ and a speed of 20-30m / min.

[0029] S7. Second setting: After washing and drying, the fabric is impregnated with softener on a setting machine, then set and dried by hot air stretching, and 20g / L of raising agent and 2g / L of penetrating agent are added. The pH is adjusted to 6 with acetic acid, and the machine speed is controlled at 50m / min and the temperature is 150℃.

[0030] S8. Loose drying: After the velvet enters the flat net loose drying machine, it is conveyed forward in a wave-like shape. The temperature is 130-135℃, the overfeed is 18-22%, and the speed is 15-16 meters / minute. The fabric is patted to make it feel fluffy, and stress is released at the same time to improve shrinkage.

[0031] This invention solves the industry challenge of balancing multiple performance aspects of composite functional fabrics, including moisture absorption and heat generation, breathability and warmth retention, linting and pilling, softness and dimensional stability, through a unique material combination, precise process design, and the synergistic effect of multiple key steps. Furthermore, through innovative spinning processes and yarn treatments, the moisture absorption and conductivity of the yarn are improved, enhancing the fabric's moisture absorption and heat generation capabilities as well as its breathability, while keeping the inner layer against the skin drier. A special process is used during the napping of the fabric, resulting in short, dense, fluffy, and neatly arranged nap on the surface, improving warmth retention while mitigating the linting and pilling problems associated with ordinary napping.

[0032] This invention innovatively designs a full-chain solution for the special combination of "modal / cotton + spandex + acrylic / wool" by "yarn pretreatment enhancement (S2) → structured weaving (S3) → setting and napping aid (S4) → fine napping finishing (S5) → stress release (S8)". In particular, it strengthens the inner yarn during the dyeing stage to cope with subsequent napping, and uses loose drying in the final process to specifically solve the shrinkage problem of elastic napped fabrics.

[0033] This invention utilizes a special treatment in step S2, yarn dyeing: after dyeing, the inner layer yarn is treated with glycerol and polyurethane to allow the yarn to absorb and cross-link. The strong water absorption capacity of glycerol further enhances the yarn's hygroscopicity. The subsequent cross-linking film-forming reaction of polyurethane under radio frequency drying conditions forms a flexible protective film on the fiber surface, significantly strengthening the inner layer yarn and reducing fiber breakage and shedding during the subsequent vigorous napping process. This results in a full, fluffy pile while effectively improving the fabric's anti-pilling and anti-shedding properties. Step S5 involves staged napping and finishing: employing a combination of "three-stage napping → calendering → shearing." The three napping stages progressively strengthen the nap, ensuring even and thorough raising with minimal damage to the base fabric; calendering orients and straightens the nap, imparting luster; shearing ensures uniform nap length and a smooth, high-end appearance. This combination of processes is crucial for obtaining a high-quality, consistent nap. Step S8, loose drying: After final shaping, wave-like conveying and patting drying are added, which can fully release the internal stress accumulated in the fabric during weaving and napping, greatly improve the dimensional stability of the finished product (reduce shrinkage rate), and make the fabric feel more fluffy and soft.

[0034] In this invention, the effects of each step are mutually reinforcing and supportive. Without the yarn reinforcement in step S2, the intense pilling in step S5 could severely damage the fabric; without the loose drying in step S8, the internal stress from the pilling in step S5 and the weaving in step S3 would lead to severe shrinkage and deformation of the fabric after washing. This synergistic effect between processes produces an overall effect of "1+1>2", ultimately achieving an excellent balance between seemingly contradictory properties of the fabric (such as rich nap and low pilling, high elasticity and low shrinkage).

[0035] The above description is only a preferred embodiment of the present invention, but the present invention should not be limited to the content disclosed in the embodiments and drawings. Therefore, any equivalent or modified embodiments made without departing from the spirit of the present invention shall fall within the protection scope of the present invention.

Claims

1. A cotton-moisture wool air-layer textile material, characterized in that... include: The air layer consists of an outer layer, a middle layer, and an inner layer, wherein the middle layer is a spandex layer, the outer layer is a modal cotton blend layer, and the inner layer is an acrylic wool blend layer. The air layer textile material is manufactured through the following processes: S1. Spinning: Viscose, acrylic, and wool are spun together to obtain the inner layer yarn; Modal and cotton are spun together to obtain the outer layer yarn. S2. Yarn Dyeing: Both the inner and outer yarns are dyed using cone dyeing after spinning. For the inner yarn, after dyeing, glycerol and polyurethane are added to the dyeing vat to treat the yarn. The formula and process are as follows: glycerol 10-20 g / L; polyurethane 5-10 g / L; acetic acid 0.1-0.3 g / L, controlled temperature 60-80℃, time 15-20 min. After treatment, the water is drained, and the cone yarn is dried using an RF dryer. Simultaneously, the inner yarn undergoes a cross-linking reaction with the glycerol and polyurethane. S3. Fabric weaving: The air layer fabric is woven into the designed fabric structure using a circular knitting weft knitting machine. The inner layer is a blend of viscose, acrylic, and wool yarns, the outer layer is a blend of modal and cotton yarns, and the middle layer is connected with spandex. Bare spandex is added during the weaving process to increase elasticity. S4. First setting: After the fabric is impregnated with a napping agent on the setting machine, it is then set and dried by hot air stretching, and 10-30g / L of napping agent and 1-3g / L of penetrant are added. The machine speed is 40-60m / min and the temperature is 130-160℃. S5. Nailing: Nail the inner layer of the fabric. Use a 6-box 48-roll napping machine to nap three times. After napping, iron the fabric and then trim the nap. S6. Washing: The napped fabric is treated with a washing machine to remove lint and dust at a temperature of 30-50℃ and a speed of 20-30m / min. S7. Second setting: After washing and drying, the fabric is impregnated with softener on a setting machine, then set and dried by hot air stretching, and 10-30g / L of hydrophilic softener and 1-3g / L of penetrant are added. The pH is adjusted to 5-7 with acetic acid, and the machine speed is controlled at 40-60m / min and the temperature is 130-160℃. S8. Loose drying: After the velvet enters the flat net loose drying machine, it is conveyed forward in a wave-like shape. The temperature is 130-135℃, the overfeed is 18-22%, and the speed is 15-16 meters / minute. The fabric is patted to make it feel fluffy, and stress is released at the same time to improve shrinkage.

2. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S1, the twist of the outer yarn is controlled to be 85-100 twists / 10cm, and the twist of the inner yarn is controlled to be 95-115 twists / 10cm.

3. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S5, the first napping roller rotates at 600-800 rpm, the fabric speed is 8-12 m / min, and the tension is 10-13 N; the second napping roller rotates at 800-1000 rpm, the fabric speed is 12-16 m / min, and the tension is 13-16 N; the third napping roller rotates at 1000-1200 rpm, the fabric speed is 16-20 m / min, and the tension is 16-19 N.

4. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S5, the temperature of the heat-pressing roller is 80℃ and the fabric speed is 20m / min.

5. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S5, the hair is trimmed after ironing, with the trimmer speed at 800 rpm and the fabric speed at 8 m / min.

6. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S2, the formulation process is as follows: glycerol 15g / L; polyurethane 8g / L; acetic acid 0.2g / L, with the temperature controlled at 70℃ and the time at 20min.

7. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S4, 20 g / L of hair-raising agent and 2 g / L of penetrant are added, the machine speed is 50 m / min, and the temperature is 150℃.

8. The cotton-moisture wool air-layer textile material as described in claim 1, characterized in that: In step S7, 20 g / L of hair-raising agent and 2 g / L of penetrant are added, the pH is adjusted to 6 with acetic acid, and the speed is controlled at 50 m / min and the temperature at 150°C.

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