Production process of brocade nylon cotton-like embossed cloth and brocade nylon cotton-like embossed cloth

Abstract

This invention provides a manufacturing process for a nylon-spandex imitation cotton textured fabric, comprising the following steps: S10, weaving: nylon and spandex are fed into a circular knitting machine to weave into a greige fabric; S20, pre-setting: the greige fabric undergoes pre-setting treatment; S30, scouring and relaxation: the pre-set greige fabric is scouring and relaxation treatment under low tension conditions; S4, alkali reduction: the scouring and relaxed greige fabric is impregnated with a working solution and then subjected to steaming or cold piling reaction, followed by water washing after the reaction; S5, dyeing: acid dyes, neutral dyes, or disperse dyes are used to dye the alkali-reduced greige fabric, controlling the temperature rise curve and dye bath pH value during the dyeing process, followed by soaping and color fixing treatment; S6, softening and setting: the dyed greige fabric is impregnated with a softener and then set to obtain the nylon-spandex imitation cotton textured fabric. The process of this invention achieves a cotton-like textured fabric with uniform dyeing, high color fastness, clear and durable textured patterns, stable dimensions, and no pilling or fuzzing.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and in particular to a manufacturing process and a nylon-spandex imitation cotton embossed fabric. Background Technology

[0002] With its textured surface, unique visual depth, and tactile feel, embossed fabric is highly favored in high-end clothing and home décor, becoming a popular fabric type that combines aesthetics and practicality.

[0003] Traditional embossed fabrics are mostly made from cotton yarn. Cotton fibers are hollow and crimped, resulting in a loose fabric structure with large pores. This not only allows ultraviolet rays to penetrate easily, making it unable to provide effective sun protection, but also limits its mechanical properties. With long-term use, it is prone to deformation and wrinkling, making it difficult to maintain the three-dimensional stability of the embossed pattern. At the same time, cotton fibers are highly absorbent but dry slowly, making them prone to bacterial growth in humid environments, affecting the fabric's user experience and lifespan.

[0004] To overcome the shortcomings of cotton fiber textured fabrics, the industry has gradually begun to use nylon as a raw material for their production. Nylon, with its excellent elasticity, abrasion resistance, and stiffness, improves the mechanical properties and morphological stability of textured fabrics to some extent. It also dries quickly, is less prone to bacterial growth, and is suitable for a wider range of applications. However, the smooth surface of nylon fibers increases fiber friction after traditional cotton-like finishing processes, leading to pilling and fuzzing with prolonged use. This not only affects the appearance of the textured fabric but also shortens its lifespan. Furthermore, the nylon yarns used for weaving textured fabrics have insufficient tensile strength adaptability, making warp and weft breaks common during weaving. Combined with the dimensional stability limitations imposed by nylon's thermoplasticity, the fabric is highly susceptible to shrinkage and deformation during finishing, making it difficult to create clear, regular, and durable textured patterns. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide a manufacturing process for nylon-spandex imitation cotton embossed fabric and the nylon-spandex imitation cotton embossed fabric itself, thereby solving the problems of easy pilling and fuzzing and unstable finishing of existing embossed fabrics.

[0006] To achieve the above objectives, the technical solution proposed by this invention is as follows: In a first aspect, the present invention provides a manufacturing process for a nylon-spandex imitation cotton textured fabric, which includes the following steps: S10, Weaving: Nylon and spandex are selected as raw materials, and the nylon and spandex are fed into a circular weft machine to weave into a grey fabric; The fabric has 12 rows of 20 needles each, arranged in the following sequence: 12341243214321431234. Needles 1, 2, 3, and 4 correspond to needles #1, #2, #3, and #4, respectively. Each row of the fabric is threaded with both nylon and spandex, arranged in a triangular configuration. Knit in circles using size 3 needles on rows 1, 3, and 7; knit in circles using all other needles. Knit in circles using needle 1 on rows 2, 6, and 10; knit in circles using all other needles. Knit in circles using size 4 needles on rows 4, 9, and 12; knit in circles using all other needles. Knit in circles using size 2 needles on rows 5, 8, and 11; knit in circles using all other needles. S20. Pre-setting: Pre-setting the grey fabric at a temperature of 180-190℃ for 30-40 seconds, with an overfeed of 3%-5%. S30, Refining and Relaxation: The pre-shaped fabric is refined and relaxed under low tension conditions to remove spinning oil and weaving sizing agent; S40, Alkali Reduction: After the refined and relaxed fabric is impregnated with the working solution, it is subjected to steaming or cold piling reaction. After the reaction is completed, it is washed with water. The working solution, calculated per liter of water, includes the following weight formula components: sodium hydroxide 15-25g / L, penetrant JFC 2-4g / L, amine swelling agent 5-10g / L and alkali-resistant defoamer 0.5-1g / L. S50. Dyeing: Acid dyes, neutral dyes, or disperse dyes are used to dye the greige fabric after alkali reduction. The temperature rise curve and dye bath pH value are controlled during the dyeing process. After dyeing, soaping and color fixing treatment are performed. S60, Softening and Shaping: After dyeing the greige fabric, it is impregnated with a softener and then shaped to obtain a nylon-ammonia imitation cotton textured fabric.

[0007] Preferably, in step S10, the nylon used is 70D / 68F fully dull lightweight mesh high-elastic nylon, and the spandex used is 30D acid-dyeable spandex. The fully dull characteristics of the 70D / 68F fully dull lightweight mesh high-elastic nylon yarn can effectively enhance the cotton-like visual effect of the fabric and avoid the inherent luster of nylon. The lightweight mesh structure ensures the elasticity of the fiber and the cohesion during the weaving process, while the high elasticity gives the fabric excellent tensile recovery performance. The 30D acid-dyeable spandex not only has good elasticity but can also be dyed simultaneously with nylon, ensuring the uniformity of fabric dyeing and avoiding color variations and color differences caused by the inability to dye spandex. At the same time, the addition of spandex can effectively improve the dimensional stability of nylon fabric and solve the shrinkage and deformation problems caused by the thermoplasticity of nylon.

[0008] Preferably, in step S20, the fabric is impregnated with an anti-yellowing agent before molding to prevent yellowing caused by amino oxidation of the fibers.

[0009] Preferably, in step S30, refining and relaxation are performed using a flat-width loose-type washing machine at a processing temperature of 80-95℃, with degreasing agent and chelating dispersant as the auxiliary agents, and a machine speed of 20-30m / min; or a high-temperature and high-pressure overflow dyeing machine is used, with treatment at 95-98℃ for 20-30min, and 1-2g / L of refining agent and 1-2g / L of soda ash as the auxiliary agents.

[0010] Preferably, in step 40, the pH value of the padding groove is above 13; the liquid content of the fabric is 70-85%; the padding temperature is room temperature; the steam reaction conditions are saturated steam treatment at 100-102℃ for 8-15 minutes; and the cold stacking reaction conditions are stacking at room temperature for 12-24 hours.

[0011] Preferably, in step S40, the water washing process is as follows: first, the fabric is washed twice with hot water above 85°C to remove the swollen and peeled oligomers; then, the pH of the fabric is neutralized to 6.5-7.5 with 1-2 g / L glacial acetic acid at 50-60°C; finally, the fabric is rinsed with cold water.

[0012] Preferably, in step S50, the dyeing temperature rise curve is as follows: under room temperature conditions, add leveling agent, acid-releasing agent or pH-sliding agent, and dye to the dye bath and run for 5-10 minutes, raise the temperature to 60°C at 0.5°C / min, raise the temperature to 80°C at 1.0°C / min, raise the temperature to 98°C at 1.5°C / min, hold at this temperature for 30-40 minutes, lower the temperature to 75°C at 1.2°C / min, and then lower the temperature to 45°C to drain the solution; the pH of the dye bath is controlled at 4.5-5.5.

[0013] Preferably, in step S50, the soaping and color-fixing process is as follows: after dyeing, the solution is drained, and then successively washed with hot water, washed with cold water, treated with a color-fixing agent at 50°C for 30 minutes, washed with hot water, and then removed from the vat.

[0014] Preferably, in step S60, the softener is hydrophilic amino silicone oil or cotton-like silicone oil, and the dosage is 20-40 g / L; the setting temperature is 150℃-180℃, the machine speed is 20-25 m / min, and the setting width is 2-3 cm wider than the finished product width.

[0015] Secondly, the present invention provides a nylon-spandex imitation cotton textured fabric produced using the manufacturing process of the present invention.

[0016] By adopting the above technical solution, the beneficial effects of the present invention are as follows: This invention uses nylon and spandex as raw materials and weaves them through a unique complete structure, effectively solving the problems of warp and weft breaks in the existing nylon embossed fabric weaving process. The synergistic effect of nylon and spandex can also improve the defects of poor dimensional stability and easy shrinkage and deformation caused by the thermoplasticity of nylon itself. Subsequent steps, such as pre-setting, low-tension refining and relaxation, alkali reduction with specific components and processes, dyeing with controllable temperature rise curve and pH value, soaping and color fixing, and softening and shaping, are adapted to the weaving structure. The alkali reduction achieves the cotton-like effect of the fabric, while ensuring dyeing uniformity and color fastness. Finally, a nylon-spandex cotton-like embossed fabric with clear and lasting embossed patterns, stable dimensions, and no pilling is produced. Attached Figure Description

[0017] Figure 1 This is a triangular configuration diagram of the fabric according to a preferred embodiment of the present invention. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0019] This invention provides a manufacturing process for a nylon-spandex imitation cotton textured fabric, comprising the following steps: S10, Weaving Using 70D / 68F fully dull lightweight mesh high-elastic nylon and 30D acid-dyeable spandex as raw materials, the nylon and spandex are fed into a circular knitting machine and processed according to... Figure 1 The triangular configuration shown is woven into a greige fabric. The yarn length of nylon is 22.5 cm / 100 N, the yarn length of spandex is 7.5 cm / 100 N, the yarn ratio of nylon is 87.5%, and the yarn ratio of spandex is 12.5%.

[0020] Figure 1 In the diagram, "∩" indicates a loop being pulled up from the bottom of the needle cylinder, and "∧" indicates a loop being formed from the bottom of the needle cylinder. A complete weave of the grey fabric has 12 rows, each with 20 needles, arranged in the following order: 12341243214321431234. Needles 1, 2, 3, and 4 correspond to needle sizes 1, 2, 3, and 4, respectively. Each row of the complete weave uses both nylon and spandex, arranged in a triangular configuration: Knit in circles using size 3 needles on rows 1, 3, and 7; knit in circles using all other needles. Knit in circles using needle 1 on rows 2, 6, and 10; knit in circles using all other needles. Knit in circles using size 4 needles on rows 4, 9, and 12; knit in circles using all other needles. Knit in circles using size 2 needles on rows 5, 8, and 11; knit in circles using all other needles. The 12-row x 20-needle weave, combined with a specific needle arrangement, ensures even yarn stress during knitting, reducing warp and weft breaks. The triangle configuration features an irregularly distributed, diamond-shaped loop design, with the loops randomly distributed across each row, creating a dynamic and natural jagged effect. Simultaneously, both nylon and spandex are fed into each row. The difference in shrinkage between these two yarns is further accentuated during subsequent pre-setting, refining, and relaxation processes, resulting in a three-dimensional and full-bodied raised pattern layered on top of the jagged effect.

[0021] Note: Yarn length usually refers to the length of yarn required to form a loop in a knitted fabric, also known as loop length. In actual production, it is often measured by the total length of 50 or 100 loops, referred to as 50-gauge yarn length and 100-gauge yarn length, respectively.

[0022] S20, Pre-order type First, the grey fabric is impregnated with an anti-yellowing agent (such as TF-621A) to prevent yellowing of nylon and spandex due to amino oxidation during high-temperature setting, ensuring the whiteness of the grey fabric and laying the foundation for subsequent dyeing. Then, a pre-setting treatment is performed at 180-190℃ for 30-40 seconds, with an overfeed of 3-5%. These parameters eliminate internal stress generated during weaving, stabilize the width and weight of the grey fabric, effectively fix the fabric's structure and the initial shape of the raised pattern, prevent the raised pattern from being flattened, and prevent high temperatures from damaging the fiber properties.

[0023] S30, Refining and Relaxing The refining and relaxation processes employ a low-tension treatment to avoid excessive tension that could deform the raised pattern. Two specific treatment methods are available: Method 1: Use a flat-width loose washing machine at a temperature of 80-95℃. Use degreasing agents (such as TF-109HB) and chelating dispersants (such as TF-133F) as auxiliaries. The machine speed is 20-30 m / min. This method, through low-tension conveying and gentle temperature conditions, removes spinning oils and weaving sizing agents while allowing the fibers to fully shrink and retract, increasing the fabric's bulk and improving its cotton-like feel. Method 2: Use a high-temperature, high-pressure overflow dyeing machine for treatment at 95-98℃ for 20-30 minutes. Use 1-2 g / L refining agent and 1-2 g / L soda ash as auxiliaries. This method uses a high-temperature, high-pressure environment to quickly and efficiently remove impurities while promoting fiber relaxation, making it suitable for production needs of different batches.

[0024] Both treatment methods can achieve sufficient fiber relaxation and effective removal of impurities while ensuring the stability of the floating pattern, thus providing favorable conditions for the subsequent alkali reduction process.

[0025] S40, Alkali Reduction The refined and relaxed fabric is impregnated with the working solution at room temperature. Room temperature avoids the decomposition of the alkali solution caused by high temperature, thus ensuring a uniform and stable reaction. The pH value of the working solution is maintained above 13. The liquid content of the impregnated fabric is controlled at 70-85%. Too high a liquid content can easily lead to dripping and cause violent local reactions in the fabric, while too low a liquid content will result in insufficient reaction. This range ensures a uniform and stable reaction.

[0026] The working solution described above, calculated per liter of water, comprises the following components by weight: sodium hydroxide 15-25 g / L, penetrant JFC 2-4 g / L, amine swelling agent 5-10 g / L, and alkali-resistant defoamer 0.5-1 g / L. Sodium hydroxide, as the primary etching agent, uniformly etches the surface of nylon fibers, creating a rough surface similar to cotton fibers, laying the foundation for the cotton-like feel. Penetrant JFC promotes rapid wetting of the fibers by the alkali solution, ensuring uniform etching. The amine swelling agent promotes fiber swelling, assisting in alkali penetration and etching, further enhancing the fabric's fluffiness and cotton-like texture. The alkali-resistant defoamer prevents excessive foam generation during the reaction, avoiding uneven coloring defects on the fabric.

[0027] The working solution of this invention can be prepared according to the raw material ratio of the embodiment in Table 1, that is, the corresponding weight of the formula components is added to water to form the working solution per liter of water.

[0028] Table 1 Working fluid raw material ratio

[0029] The reaction stage can be selected by steaming or cold stacking according to production needs: the steaming reaction condition is 100-102℃ saturated steam treatment for 8-15 minutes, which has high reaction efficiency and is suitable for continuous industrial production; the cold stacking reaction condition is to stack at room temperature for 12-24 hours and wrap it with plastic film to prevent it from drying out. This method has a mild reaction and the fabric is more fluffy and soft, which is suitable for small-batch customized production.

[0030] After the reaction is complete, a water washing process is performed as follows: First, wash twice with hot water above 85℃ to fully remove the oligomers that swell and peel off during the reaction, so as to avoid affecting subsequent dyeing. Then, neutralize the pH of the fabric to 6.5-7.5 with 1-2 g / L glacial acetic acid at 50-60℃. Thorough neutralization prevents residual alkali from causing color spots and color differences. Finally, rinse with cold water overflow to remove residual acetic acid and salts, ensuring that the pH value of the fabric meets the standard, and providing a clean and stable fabric base for subsequent dyeing.

[0031] S50, staining Dyes and auxiliaries are selected to dye the greige fabric after alkali reduction. The dyes are acid dyes or neutral dyes (for nylon) and disperse dyes (for spandex), and the auxiliaries are acid-releasing agents or pH-sliding agents and leveling agents.

[0032] At room temperature, add auxiliaries and dyes to the dye bath and run for 5-10 minutes to ensure uniform dispersion of the dyes and auxiliaries. Then, increase the temperature at 0.5℃ / min to 60℃, 1.0℃ / min to 80℃, and 1.5℃ / min to 98℃, holding for 30-40 minutes to ensure full dye penetration and fixation within the fibers. Finally, decrease the temperature at 1.2℃ / min to 75℃, then further decrease to 45℃ to drain the dye bath. Slow cooling avoids sudden temperature changes that could cause uneven fabric shrinkage and affect the stability of the raised pattern. Maintain the pH of the dye bath at 4.5-5.5, using an acid-releasing agent or pH-sliding agent to slowly release H+ under neutral to weakly acidic conditions. + Control the dyeing rate to ensure simultaneous and uniform dyeing of nylon and spandex, and avoid color variations and uneven coloring.

[0033] After dyeing, the fabric undergoes soaping and color-fixing treatment. The treatment process is as follows: After dyeing, the dye is drained and then washed with hot water and cold water in sequence to remove surface dye. Then, it is treated with a color-fixing agent at 50℃ for 30 minutes to enhance the fixation of the dye on the fiber and improve the fabric's color fastness to rubbing and soaping. Finally, it is washed with hot water to remove the residual color-fixing agent and then removed from the dye bath for later use.

[0034] S60, Soft Shaping After dyeing, the greige fabric is impregnated with hydrophilic amino silicone oil at a dosage of 20-40 g / L to improve its skin-friendliness and breathability. Alternatively, a cotton-like silicone oil can be used to enhance the fabric's cotton-like texture. Then, a setting treatment is performed at a setting temperature of 150-180℃ and a machine speed of 20-25 m / min. The setting width is 2-3 cm wider than the finished width to allow for natural shrinkage, effectively controlling the fabric's warp and weft shrinkage rates, ensuring dimensional stability, and further fixing the raised pattern, making the pattern more three-dimensional and durable.

[0035] The nylon-spandex imitation cotton embossed fabric produced through the above process is made of nylon and spandex woven with a specific weave structure and finished product. Its surface features a unique pattern of overlapping random patterns and embossed textures, creating a lively, natural, and three-dimensional design. The fabric combines the excellent feel of imitation cotton with the elasticity of nylon-spandex fibers, exhibiting no pilling or fuzzing. Its dense structure effectively blocks ultraviolet rays, providing excellent sun protection. Furthermore, it boasts excellent dimensional stability, low shrinkage in both warp and weft directions, and high levels of colorfastness to rubbing and washing. It can be widely used in high-end clothing, home décor, and other fields.

[0036] The performance test results of the nylon-spandex imitation cotton textured fabric obtained by the above process are shown in Table 2.

[0037] Table 2 Performance test results of nylon-spandex imitation cotton textured fabric

[0038] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail to the invention without departing from the spirit and scope of the invention as defined in the appended claims are within the scope of protection of the invention.

Claims

1. A process for making a brocade cotton-like embossed fabric, characterized in that, Includes the following steps: S10, Weaving: Nylon and spandex are selected as raw materials, and the nylon and spandex are fed into a circular weft machine to weave into a grey fabric; The fabric has 12 rows of 20 needles each, arranged in the following sequence: 12341243214321431234. Needles 1, 2, 3, and 4 correspond to needles #1, #2, #3, and #4, respectively. Each row of the fabric is threaded with both nylon and spandex, arranged in a triangular configuration. Knit in circles using size 3 needles on rows 1, 3, and 7; knit in circles using all other needles. Knit in circles using needle 1 on rows 2, 6, and 10; knit in circles using all other needles. Knit in circles using size 4 needles on rows 4, 9, and 12; knit in circles using all other needles. Knit in circles using size 2 needles on rows 5, 8, and 11; knit in circles using all other needles. S20, Pre-setting: Pre-setting the grey fabric at a temperature of 180-190℃ for 30-40 seconds, with an overfeed of 3-5%; S30, Refining and Relaxation: The pre-shaped fabric is refined and relaxed under low tension conditions to remove spinning oil and weaving sizing agent; S40, Alkali Reduction: After the refined and relaxed fabric is impregnated with the working solution, it is subjected to steaming or cold piling reaction. After the reaction is completed, it is washed with water. The working solution, calculated per liter of water, includes the following weight formula components: sodium hydroxide 15-25g / L, penetrant JFC 2-4g / L, amine swelling agent 5-10g / L and alkali-resistant defoamer 0.5-1g / L. S50. Dyeing: Acid dyes, neutral dyes, or disperse dyes are used to dye the greige fabric after alkali reduction. The temperature rise curve and dye bath pH value are controlled during the dyeing process. After dyeing, soaping and color fixing treatment are performed. S60, Softening and Shaping: After dyeing the greige fabric, it is impregnated with a softener and then shaped to obtain a nylon-ammonia imitation cotton textured fabric.

2. The process for making brocade imitated cotton embossed cloth according to claim 1, characterized in that, In step S10, the nylon used is 70D / 68F fully dull lightweight mesh high-elastic nylon, and the spandex used is 30D acid-dyeable spandex.

3. The process for making brocade imitation cotton embossed fabric as claimed in claim 1 wherein, In step S20, the fabric is impregnated with an anti-yellowing agent before molding to prevent yellowing caused by amino oxidation of the fibers.

4. The process for making brocade imitated cotton embossed fabric as claimed in claim 1 wherein, In step S30, refining and relaxation are performed using a flat-width loose-type washing machine at a processing temperature of 80-95℃, with degreasing agent and chelating dispersant as the auxiliary agents, and a machine speed of 20-30m / min; or a high-temperature and high-pressure overflow dyeing machine is used, with treatment at 95-98℃ for 20-30min, and 1-2g / L of refining agent and 1-2g / L of soda ash as the auxiliary agents.

5. The process for making brocade imitated cotton embossed cloth as claimed in claim 1 wherein, In step 40, the liquid content of the fabric is 70-85%, the impregnation temperature is room temperature, the steam reaction conditions are saturated steam treatment at 100-102℃ for 8-15 minutes, and the cold stacking reaction conditions are stacking at room temperature for 12-24 hours.

6. The process for making brocade imitated cotton embossed cloth as claimed in claim 1 wherein, In step S40, the water washing process is as follows: First, the fabric is washed twice with hot water above 85°C to remove the swollen and peeled oligomers. Then, the pH of the fabric is neutralized to 6.5-7.5 with 1-2 g / L glacial acetic acid at 50-60°C. Finally, the fabric is rinsed with cold water.

7. The process for making brocade imitation cotton embossed fabric as claimed in claim 1 wherein, In step S50, the dyeing temperature rise curve is as follows: Under room temperature conditions, add leveling agent, acid release agent or pH shifting agent, and dye to the dye bath and run for 5-10 min. Increase the temperature to 60℃ at 0.5℃ / min, increase the temperature to 80℃ at 1.0℃ / min, increase the temperature to 98℃ at 1.5℃ / min, hold at this temperature for 30-40 min, decrease the temperature to 75℃ at 1.2℃ / min, and then decrease the temperature to 45℃ to drain the solution. The pH of the dye bath is controlled at 4.5-5.

5.

8. The manufacturing process of the nylon-spandex imitation cotton textured fabric according to claim 1, characterized in that, In step S50, the soaping and color-fixing process is as follows: after dyeing, the solution is drained, followed by hot water washing, cold water washing, color-fixing agent treatment at 50°C for 30 minutes, and hot water washing before being removed from the vat.

9. The manufacturing process of the nylon-spandex imitation cotton textured fabric according to claim 1, characterized in that, In step S60, the softener is hydrophilic amino silicone oil or cotton-like silicone oil, and the dosage is 20-40 g / L; the setting temperature is 150℃-180℃, the machine speed is 20-25 m / min, and the setting width is 2-3 cm wider than the finished product width.

10. A nylon-spandex imitation cotton textured fabric manufactured using the manufacturing process described in any one of claims 1 to 9.

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