Processing method of thick plush fabric

Abstract

The invention provides a processing method of a thick plush fabric, and relates to the technical field of textiles. The processing method of the thick plush fabric sequentially comprises the working procedures of weaving, dyeing, post-shaping and napping finishing, and is characterized in that after the working procedure of weaving and before the working procedure of dyeing, an air heating penetrating and beating working procedure is adopted to replace a traditional pre-shaping working procedure; the specific process of the air heating penetrating and flapping procedure is that the fabric is subjected to penetrating and flapping effects of high-speed hot air flow with the flow speed being 30-70 m / s in a loose or low-tension state, and meanwhile the environment temperature is maintained to be 90-170 DEG C. The method can effectively improve the bulkiness, softness and non-deformability of the finished product.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of textiles, in particular to a processing method of thick pile fabric. BACKGROUND

[0002] Thick pile fabrics, such as Sherpa, mink, and fleece, are widely used in home textiles, clothing, toys, and other fields due to their excellent warmth retention and full appearance. The traditional processing flow usually includes weaving, opening, pre-setting, dyeing, post-setting, and napping finishing (including blowing, combing, shearing, and ironing steps).

[0003] Among them, pre-setting is one of the key processes, which mainly stabilizes the fiber structure, eliminates internal stress, and lays the foundation for subsequent dyeing processing by using high temperature, tension, and time, preventing the fabric from shrinking or deforming during dyeing.

[0004] However, this traditional pre-setting process has inherent defects: high temperature and large tension can "lock" the fibers in the fabric into a relatively tight and rigid state. Although this ensures dimensional stability, it sacrifices the final loftiness and softness of the fabric. After this process, even if subsequent napping treatment is performed, the core of the fabric is still not soft enough, resulting in a hard, thick, and lack of elasticity, poor recovery after being pressed, affecting the comfort of use and the quality of the product.

[0005] Therefore, there is an urgent need in the art for a new processing method that can ensure the dimensional stability and production efficiency of the fabric while giving the warp-knitted thick pile a more excellent loftiness, softness, and better crispness and anti-deformation ability. SUMMARY

[0006] (I) Technical problems solved

[0007] The purpose of the present application is to overcome the shortcomings of the prior art and provide a processing method for warp-knitted thick pile fabric that can effectively improve the loftiness, softness, and anti-deformation ability of the finished product.

[0008] (II) Technical solutions

[0009] To achieve the above purpose, the present application is implemented by the following technical solutions:

[0010] In a first aspect, the present application provides a processing method for thick pile fabric, which includes replacing the traditional pre-setting process with an air-heated penetration and beating process after the weaving process and before the dyeing process. The specific process of the air-heated penetration and beating process is as follows: the fabric is subjected to high-speed hot air penetration and beating while maintaining the ambient temperature at 90-170℃ in a relaxed or low-tension state.

[0011] Preferably, the flow rate of the high-speed hot air stream is 30-70 m / s.

[0012] Preferably, the ambient temperature of the air-heating penetrating beating process is preferably 110-130℃, more preferably 120℃.

[0013] Preferably, the high-speed hot air stream is generated by a Venturi effect, using the pressure difference formed by the airflow on the upper and lower surfaces of the fabric to physically beat and oscillate the fabric.

[0014] Preferably, the weaving is carried out using a double needle bed warp knitting machine, and the yarns used include ground yarns and face yarns; the ground yarns are 50D-150D polyester fiber FDY filaments, and the face yarns are 50D-100D polyester fiber FDY filaments or ultrafine denier polyester fibers.

[0015] Preferably, after the air-heating penetrating beating process, dyeing, post-setting and napping finishing processes are sequentially carried out.

[0016] Preferably, the temperature of the post-setting process is 170-200℃, and the running speed is 15-25 m / min.

[0017] Preferably, the napping finishing process includes carding, shearing and glazing, wherein the carding uses flexible steel wire needles with medium density and high elasticity, the cloth speed is controlled at 8-12 m / min, and multiple front and back napping is carried out.

[0018] In a second aspect, the present application provides a thick pile fabric, which is processed by the above-mentioned method, and the fabric has a grammage of 300-1000 gsm.

[0019] (Three) beneficial effects

[0020] (1) The present application fundamentally changes the fiber state of the fabric at the initial stage of processing by replacing the traditional "high-temperature tension pre-setting" with the physical finishing method of "air-heating penetrating beating". The penetration and beating of the high-speed airflow on the fabric can effectively break down the internal stress between the fibers, making the fiber structure loose and fluffy, rather than being forcibly compressed and set by high temperature and tension. This lays the foundation for the excellent softness and fluffiness of the final product.

[0021] (2) The processing method of a thick pile fabric according to the present application, since the fabric has obtained a fluffy structure before dyeing, and this structure is preliminarily fixed in the subsequent heat treatment, the final product has a softer, fuller and smoother hand feeling, completely changing the stiffness and heaviness of traditional thick pile fabrics.

[0022] (3) The processing method of the thick pile fabric of the present application, the fabric treated by the method of the present application has better natural elasticity of the fibers, so that the fabric can recover to the original state faster and better after being pressed or folded, has excellent wrinkle resistance and deformation resistance, and has stronger crispness.

[0023] (4) The processing method of the thick pile fabric of the present application, the process replaces the pre-setting and does not significantly increase the process or equipment complexity (can be completed on the modified setting machine or special airflow equipment), realizes the leap of product quality under the premise of not increasing or even possibly reducing energy consumption and cost.

[0024] (5) The processing method of the thick pile fabric of the present application, the method is particularly suitable for high-grammage warp-knitted pile fabric, and can effectively solve the industry problem that it is more difficult to obtain soft hand feeling due to high gram weight. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 The figure is a flowchart of the processing method of the thick pile fabric in the embodiment of the present application.

[0026] Figure 2 The figure is an example of the automatic production line for processing the thick pile fabric in the embodiment of the present application. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0028] EMBODIMENT

[0029] Please refer to Figure 1 The embodiment of the present application provides a processing method of a thick pile fabric, which comprises replacing the traditional pre-setting process with an air heating penetration and beating process after the weaving process and before the dyeing process; the specific process of the air heating penetration and beating process is that the fabric is subjected to the penetration and beating of high-speed hot air flow in a relaxed or low-tension state, and the ambient temperature is maintained at 90-170℃.

[0030] In some embodiments, the flow rate of the high-speed hot air flow is 30-70 m / s.

[0031] In some embodiments, the ambient temperature of the air heating penetration and beating process is preferably 110-130℃, and more preferably 120℃.

[0032] In some embodiments, the high-speed hot air flow is generated by a Venturi effect, which physically pats and shakes the fabric by using the pressure difference formed by the airflow on the upper and lower surfaces of the fabric.

[0033] In some embodiments, the weaving is performed by using a double needle bed warp knitting machine, and the yarns used include ground yarns and face yarns; the ground yarns are polyester fiber FDY filaments with a fineness of 50D-150D, and further, the face yarns are polyester fiber FDY filaments or ultrafine denier polyester fibers with a fineness of 50D-100D.

[0034] In some embodiments, after the air heating penetration patting process, the dyeing, post-setting and napping finishing processes are sequentially performed.

[0035] In some embodiments, the temperature of the post-setting process is 170-200℃, and the running speed is 15-25m / min.

[0036] In some embodiments, the napping finishing process includes carding, shearing and glazing, wherein the carding is performed by using flexible steel wire clothing with a medium density and high elasticity, the cloth speed is controlled at 8-12m / min, and the napping is performed on the front and back surfaces for multiple times.

[0037] Experimental verification of the technical effect of the method of the present application:

[0038] The technical effect of the present application is verified by actually processing high-grammage warp-knitted jersey fabric, and the specific process is as follows:

[0039] (1) Raw material preparation and weaving:

[0040] Ground yarn (yarn A): 100D / 36F semi-dull polyester fiber FDY filaments are selected.

[0041] Face yarn (yarn B): 75D / 36F full-dull polyester fiber FDY filaments are selected to enhance the softness of the pile surface.

[0042] Equipment: a high-speed double needle bed warp knitting machine is used.

[0043] Process parameters: the warp feed of warp beam 1 (usually used for ground yarn) is 4800mm / rack; the warp feed of warp beam 2 (usually used for face yarn) is 15000mm / rack; the main shaft rotation speed is set to 900rpm; and the total stitch height is 2.

[0044] (2) Air heating penetration patting (instead of pre-setting):

[0045] Equipment: a finishing equipment with a Venturi tube type air blowing device is used.

[0046] Process parameters: the woven fabric is fed into the device under low tension. Hot air flow with a flow rate of about 50 m / s is generated in the device, and the temperature of the hot air is set to 120℃. The high-speed hot air penetrates the fabric base cloth, and the fabric is continuously and uniformly physically patted and oscillated by the pressure difference between the upper and lower parts, and the processing time is about 1-3 minutes. During this process, the internal stress of the fabric fiber is effectively eliminated, and the structure becomes fluffy, and at the same time, in the hot environment of 120℃, the fluffy structure is preliminarily shaped.

[0047] (3) Dyeing:

[0048] Pre-treatment: the fabric is first refined to remove weaving oil and impurities.

[0049] Dyeing: high-temperature and high-pressure overflow dyeing machine is used. According to the characteristics of high weight, the temperature rising and falling rate and the dyeing liquid circulation speed are strictly controlled to ensure uniform dyeing and no color phenomenon.

[0050] (4) Post-shaping:

[0051] Equipment: tentering setting machine.

[0052] Process parameters: set the temperature to 185℃ and the speed to 20 m / min. Through this process, the final stable width and weight of the fabric are given.

[0053] (5) Suede finishing:

[0054] Carding: select flexible steel wire needle cloth with medium density and high elasticity, control the cloth speed at 10 m / min, and maintain low tension. First, carry out 4 passes of front carding, and then carry out 2 passes of back light carding to remove impurities and make the roots of the suede more fluffy. Check the suede between each pass and adjust the parameters.

[0055] Shearing: use a shearing machine to shear the suede to a uniform height of 20 mm.

[0056] Glazing: process through a glazing machine to make the suede hair lie down, the gloss is soft, and the final texture is improved.

[0057] Comparative example

[0058] Use the same raw materials and weaving parameters as the traditional process, and change the subsequent process to: weaving → opening → traditional pre-shaping (190℃, high tension) → dyeing → post-shaping → suede finishing.

[0059] The fabric obtained by the example of the application and the fabric of the comparative example are compared and tested, and the results are as follows:

[0060] Test items Example fabrics Comparative fabrics Subjective evaluation of hand Extremely fluffy, soft, and smooth Relatively stiff, thick, and heavy Compression elastic recovery rate ≥85％ ≈70％ Drape coefficient Smaller, natural drape Larger, feeling stiff Weight per unit area Feeling light and warm Feeling heavy

[0061] From the above table, it can be seen that the fabric processed by the method of the application is significantly better than the fabric produced by the traditional method in terms of hand feeling, fluffiness and elastic recovery performance.

[0062] The existing warp-knitted pile production is usually completed by discrete single machines, such as warp knitting machine, setting machine, dyeing machine, raising machine, etc. arranged in series. The grey fabric needs to be transported, loaded and unloaded and stored for many times between each process.

[0063] Please refer to Figure 2 The embodiment of the present application also provides an automatic production line for processing thick pile fabric, which comprises, in sequence along the material flow direction, a warp-knitting unit, a grey fabric conveying mechanism, an air-heating and beating finishing unit, a dyeing unit, a post-setting unit and a raising finishing unit. All these units are communicated and cooperatively controlled by a central control system (not shown in the figure, usually a control system composed of industrial computer and PLC).

[0064] The warp-knitting unit adopts a high-speed double-needle bed warp knitting machine, and the fabric outlet thereof is connected to the subsequent unit through the grey fabric conveying mechanism (such as a series of guide rollers and conveying belt).

[0065] The air-heating and beating finishing unit is the core innovative part of the production line. The unit is internally provided with a plurality of Venturi tube type air blowing devices arranged along the fabric running direction. These air blowing devices are connected to a hot air circulating system (including a heater, a high-pressure air blower and an air duct), and can generate stable and uniform hot air flow of 50 m / s and 120℃. The fabric is carried and conveyed by a low-tension fabric conveying mechanism (in this case, a no-tension accumulated fabric conveying belt). The design of the conveying belt makes the fabric on it in a relaxed and accumulated state, so as to ensure that the high-speed air flow can fully penetrate the fabric and effectively beat by using the pressure difference between the upper and lower parts when passing through the air blowing area, without any tension damage.

[0066] The grey fabric after beating finishing directly enters the dyeing unit (in this case, a high-temperature and high-pressure overflow dyeing machine) through the first connecting device (such as a swing arm type fabric falling device or a sealed fabric guide port).

[0067] The fabric after dyeing is dehydrated and opened, and then enters the post-setting unit (in this case, a tenter setting machine) through the second connecting device.

[0068] Finally, the fabric enters the raising finishing unit through the third connecting device. The unit integrates the carding machine, the shearing machine and the glazing machine in sequence on a production line, so as to realize continuous operation of raising finishing.

[0069] The central control system receives the data (such as temperature, speed, tension) of the sensors of each unit, and uniformly sets and adjusts the process parameters of the whole line. For example, the system can link the hot air temperature of the beating unit and the set temperature of the post-setting unit to ensure the continuity of the process.

[0070] As a more preferred embodiment, at the outlet of the post-setting unit and / or the outlet of the brushing finishing unit, online quality detection devices (such as a laser or image-based loft detector, a weight detector, and a color difference detector) are provided. These detection devices send monitoring data to the central control system in real time. The intelligent algorithm built into the system can automatically fine-tune the parameters of the previous processes (such as the air flow speed of the beating unit, the formula of the dyeing unit, or the cloth speed of the brushing unit) according to the deviation of the detection results from the preset standard values, forming a closed-loop quality control loop to ensure the stability and optimization of the final product quality.

[0071] Through this automated production line, the processing method of the embodiment is efficiently, stably and intelligently executed, and the indicators of the produced fabric are uniform, and the reliable guarantee of the excellent fluffy soft hand feeling is obtained.

[0072] It should be noted that, in this document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can also include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without limitation, an element preceded by "comprises... a" does not, without more constraints, foreclose the existence of additional identical elements in the process, method, article, or apparatus.

Claims

1. A method for processing a thick plush fabric, comprising, in sequence, weaving, dyeing, post-setting, and napping finishing processes, characterized in that, After the weaving process and before the dyeing process, an air-heated penetration and beating process is used to replace the traditional pre-forming process. The specific process of the air-heated penetration and beating process is as follows: the fabric is subjected to the penetration and beating action of a high-speed hot air flow with a velocity of 30-70m / s in a relaxed or low-tension state, while the ambient temperature is maintained at 90-170℃.

2. The processing method of a thick plush fabric according to claim 1, characterized in that: The ambient temperature for the air-heated penetration and beating process is 110-130℃.

3. The processing method of a thick plush fabric according to claim 1, characterized in that: The ambient temperature for the air-heated penetration and beating process is 120°C.

4. The processing method of a thick plush fabric according to claim 1, characterized in that: The high-speed hot airflow is generated through the Venturi tube effect.

5. The processing method of a thick plush fabric according to claim 1, characterized in that: The weaving is carried out using a double needle bed warp knitting machine, and the yarn used includes a base yarn and a face yarn; the base yarn is 50D-150D polyester fiber FDY filament, and the face yarn is 50D-100D polyester fiber FDY filament.

6. The processing method of a thick plush fabric according to claim 5, characterized in that: The yarn is made of ultra-fine denier polyester fiber.

7. The processing method of a thick plush fabric according to claim 1, characterized in that: The temperature of the post-setting process is 170-200℃.

8. The processing method of a thick plush fabric according to claim 1, characterized in that: The brushing process involves combing the nap using medium-density, high-elasticity flexible steel wire needle cloth, with the cloth speed controlled at 8-12 m / min, and multiple brushing operations on both sides.

9. A thick plush fabric, characterized in that, The fabric is manufactured by the method described in any one of claims 1 to 8, wherein the weight of the fabric is controlled between 300 and 1000 gsm.

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