Preparation method of ultra-soft high-count and high-density fabric

Abstract

The present invention relates to a method for preparing a super-soft high-count and high-density fabric, comprising the following steps: (1) selecting combed long-staple cotton yarn as warp yarn; (2) drying PET particles and feeding them into a screw extruder to melt them, and then extruding them through a porous spinneret to obtain super-fine denier polyester fibers with regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the super-fine denier polyester fibers are used as weft yarns; (3) warping and sizing the warp yarns in sequence and then drawing them into a reed; (4) weaving: weaving the warp yarns and weft yarns on a jet loom using a plain weave; (5) air washing and softening treatment: immersing the fabric in a foam formed by a foaming machine, wherein the foam contains a softener, and then air washing the fabric in a super-soft finishing machine. The present invention improves the yarn, organizational structure and process of the fabric, so that the yarn strength of the high-count and high-density fabric meets the requirements while having a sufficiently soft feel.

Description

Technical Field

[0001] The invention belongs to the technical field of textile fabric production, and in particular relates to a method for preparing super-soft high-count and high-density fabric. Background Art

[0002] The so-called high-count and high-density fabric refers to a type of fabric that uses a relatively low yarn number for the warp and weft raw materials used in the production of such fabrics, and has a large warp and weft density. However, the definition of high-count and high-density fabrics should be based on the specific raw materials used. For example, for cotton fabrics, according to GB / T 5325-1997 Combed Polyester-Cotton Blended Unbleached Fabric, yarns with a linear density of 11.7tex or less can be called high-count yarns; high count is the premise of high density, and fabric density is divided into warp density and weft density. Generally, the finer the yarn count, the greater the density that can be achieved, so high-density fabrics are often based on high counts. It is customary to call fabrics with a warp density plus weft density of 800 threads / 10cm or more high-density fabrics. There are still many difficulties in the production process of current high-count and high-density fabrics. First of all, the raw materials of high-count yarns are mostly fine denier or ultra-low denier chemical fiber filaments, which have poor bundling properties and low single-filament strength. Secondly, although textiles made of natural fibers feel soft, comfortable and safe to use, their strength is weak; when natural fibers are formed into composite yarns with polyester and polyamide, although the strength of the yarn is improved, they do not have a soft enough feel. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a method for preparing ultra-soft high-count and high-density fabrics. By improving the yarn, tissue structure and process of the fabric, the yarn strength of the high-count and high-density fabrics can meet the requirements while having a sufficiently soft feel.

[0004] In order to solve the above technical problems, a technical solution adopted by the present invention is: the preparation method of the super soft high count and high density fabric comprises the following steps:

[0005] (1) Select combed long-staple cotton yarn as warp yarn;

[0006] (2) Making warp yarn: After drying, PET pellets are fed into a screw extruder to be melted, and then extruded through a porous spinneret to obtain ultra-fine denier polyester fibers with regular hexagonal pores in the cross section. The regular hexagonal pores are located near the outer circumference of the polyester fiber cross section. The ultra-fine denier polyester fibers are used as weft yarns;

[0007] (3) The warp yarns are warped and sized in sequence before being drawn into the reed;

[0008] (4) Weaving: Weaving the warp and weft yarns using plain weave on an air jet loom;

[0009] (5) Air washing and softening treatment: The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air washed in a super soft finishing machine.

[0010] Furthermore, the warp yarn density is 940-1200 yarns / inch, and the weft yarn density is 2600-3000 yarns / inch.

[0011] Furthermore, the combed long-staple cotton yarn is selected from 40-80S cotton yarn.

[0012] Furthermore, the arrangement of the multiple holes on the cross section of the ultra-fine polyester fiber is 1-2 circles with the center of the polyester fiber as the center.

[0013] Furthermore, the melting temperature of the PET particles is about 285° C., the pressure of the screw extruder is 9.5-10 MPa; the pressure of the PET melt is 180-200 MPa, and the spinning speed is 3000-4000 m / min.

[0014] Furthermore, the ultrafine denier polyester fiber has a single filament fineness of 0.4-0.6 dtex, a breaking strength of 4.7-5.2 cN / dtex, and a breaking elongation of 35%-42%.

[0015] Furthermore, the loom speed is 400-450r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage device timing is 80-202°; the weft yarn arrives at 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively.

[0016] Furthermore, the softening treatment is carried out at a temperature of 180-190° C. and for a treatment time of 1.5-2 min.

[0017] The advantages of the present invention are specifically as follows:

[0018] (1) The present invention improves the yarn, structure and process of the fabric, so that the yarn strength of the high-count and high-density fabric meets the requirements while having a sufficiently soft feel;

[0019] (2) The present invention ensures the softness of the polyester fiber by the position and shape of the porous arrangement of the porous polyester of the weft yarn, so that the fabric can be woven to have excellent softness;

[0020] (3) The present invention uses air washing to perform a softening treatment again, which ensures the strength of the fabric while making it extremely soft.

[0021] Instruction Manual

[0022] Figure 1 It is a cross-sectional view of the ultrafine denier polyester fiber. DETAILED DESCRIPTION

[0023] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation modes of the present invention are further described below in conjunction with specific drawings.

[0024] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0025] Embodiment 1:

[0026] The ultra-soft high-count and high-density fabric described in this embodiment is woven with 100% cellulose fiber in the warp yarn and 100% ultra-fine denier polyester fiber in the weft yarn; the warp yarn density is 940 yarns / inch, and the weft yarn density is 2600 yarns / inch; Figure 1 As shown, the ultra-fine denier polyester fiber is spun by a porous spinneret to obtain a porous polyester fiber. The arrangement of the porous portions on the cross section of the ultra-fine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center of the circle. The porous portions are located near the outer circumference of the polyester fiber, and the shape of the porous portions is a regular hexagon. The present invention achieves a soft hand feel of the ultra-fine denier polyester fiber by arranging the porous portions near the outer circumference of the polyester fiber through the air cavities at the porous portions.

[0027] The ultra-fine polyester fiber has a single filament fineness of 0.4 dtex, a breaking strength of 4.7 cN / dtex, and a breaking elongation of 42%.

[0028] Embodiment 2:

[0029] The method for preparing the ultra-soft high-count and high-density fabric described in this embodiment comprises the following steps:

[0030] (1) Select 40S combed long-staple cotton yarn as the warp yarn;

[0031] (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 9.5 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 180 MPa and the spinning speed is about 3000 m / min; obtaining an ultrafine denier polyester fiber having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fiber is used as weft yarn; the ultrafine denier polyester fiber has a single filament fineness of 0.4 dtex, a breaking strength of 4.7 cN / dtex, and an elongation at break of 42%;

[0032] (3) The warp yarns are warped and sized in sequence before being drawn into the reed;

[0033] (4) Weaving:

[0034] The warp and weft yarns are woven on a jet loom with a plain weave, and the loom speed is 400r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively;

[0035] (5) Air washing and softening treatment:

[0036] The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air-washed in the Aier super soft finishing machine; specifically: the softening temperature is 180℃, and the processing time is 2min; the wind-driven principle of the super soft finishing machine is adopted to suck the hot air flow into the fabric. The movement of the fabric comes entirely from the kinetic energy of the air flow, avoiding the extrusion and friction that may be caused by mechanical transmission. The air flow boundary layer has a full air cushion protection effect on the fabric, so that the fabric is treated powerfully but gently without causing damage to the fabric. After air washing, the fabric feels fluffy and has a drapey feel.

[0037] Embodiment three:

[0038] The ultra-soft high-count and high-density fabric described in this embodiment is woven with 100% cellulose fiber in the warp yarn and 100% ultra-fine denier polyester fiber in the weft yarn; the warp yarn density is 1200 yarns / inch, and the weft yarn density is 3000 yarns / inch; Figure 1As shown, the ultra-fine denier polyester fiber is spun by a porous spinneret to obtain a porous polyester fiber. The arrangement of the porous portions on the cross section of the ultra-fine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center of the circle. The porous portions are located near the outer circumference of the polyester fiber, and the shape of the porous portions is a regular hexagon. The present invention achieves a soft hand feel of the ultra-fine denier polyester fiber by arranging the porous portions near the outer circumference of the polyester fiber through the air cavities at the porous portions.

[0039] The ultra-fine polyester fiber has a single filament fineness of 0.6 dtex, a breaking strength of 5.2 cN / dtex, and a breaking elongation of 35%.

[0040] Embodiment 4:

[0041] The method for preparing the ultra-soft high-count and high-density fabric described in this embodiment comprises the following steps:

[0042] (1) Select 80S combed long-staple cotton yarn as the warp yarn;

[0043] (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 10 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 200 MPa and the spinning speed is about 4000 m / min; obtaining ultrafine denier polyester fibers having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fibers are used as weft yarns; the ultrafine denier polyester fibers have a single filament fineness of 0.6 dtex, a breaking strength of 5.2 cN / dtex, and an elongation at break of 35%;

[0044] (3) The warp yarns are warped and sized in sequence before being drawn into the reed;

[0045] (4) Weaving:

[0046] The warp and weft yarns are woven on a jet loom with a plain weave, and the loom speed is 450r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively;

[0047] (5) Air washing and softening treatment:

[0048] The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air-washed in the Aier super soft finishing machine; specifically: the softening treatment temperature is 190℃, and the treatment time is 1.5min; the wind-driven principle of the super soft finishing machine is adopted to suck the hot air flow into the fabric. The movement of the fabric comes entirely from the kinetic energy of the air flow, avoiding the extrusion and friction that may be caused by mechanical transmission. The air flow boundary layer has a full air cushion protection effect on the fabric, so that the fabric is treated powerfully but gently without causing damage to the fabric. After air washing, the fabric feels fluffy and has a drapey feel.

[0049] Embodiment five:

[0050] The ultra-soft high-count and high-density fabric described in this embodiment is woven with 100% cellulose fiber in the warp yarn and 100% ultra-fine denier polyester fiber in the weft yarn; the warp yarn density is 1000 yarns / inch, and the weft yarn density is 2800 yarns / inch; Figure 1 As shown, the ultra-fine denier polyester fiber is spun by a porous spinneret to obtain a porous polyester fiber. The arrangement of the porous portions on the cross section of the ultra-fine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center of the circle. The porous portions are located near the outer circumference of the polyester fiber, and the shape of the porous portions is a regular hexagon. The present invention achieves a soft hand feel of the ultra-fine denier polyester fiber by arranging the porous portions near the outer circumference of the polyester fiber through the air cavities at the porous portions.

[0051] The ultra-fine polyester fiber has a single filament fineness of 0.5 dtex, a breaking strength of 5.0 cN / dtex, and a breaking elongation of 36%.

[0052] Embodiment six:

[0053] The method for preparing the ultra-soft high-count and high-density fabric described in this embodiment comprises the following steps:

[0054] (1) Select 60S combed long-staple cotton yarn as the warp yarn;

[0055] (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 9.6 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 180 MPa and the spinning speed is about 3600 m / min; obtaining an ultrafine denier polyester fiber having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fiber is used as weft yarn; the ultrafine denier polyester fiber has a single filament fineness of 0.5 dtex, a breaking strength of 5.0 N / dtex, and an elongation at break of 36%;

[0056] (3) The warp yarns are warped and sized in sequence before being drawn into the reed;

[0057] (4) Weaving:

[0058] The warp and weft yarns are woven on a jet loom using plain weave, with a loom speed of 420r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively;

[0059] (5) Air washing and softening treatment:

[0060] The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air-washed in the Aier super soft finishing machine; specifically: the softening temperature is 180℃, and the processing time is 1.6min; the wind-driven principle of the super soft finishing machine is adopted to suck the hot air flow into the fabric. The movement of the fabric comes entirely from the kinetic energy of the airflow, avoiding the extrusion and friction that may be caused by mechanical transmission. The airflow boundary layer has a full air cushion protection effect on the fabric, so that the fabric is treated powerfully but gently without causing damage to the fabric. After air washing, the fabric feels fluffy and has a drapey feel.

[0061] The high count and high density fabrics prepared in Example 2, Example 4, and Example 63 were subjected to performance tests, and the results are shown in Table 1. The softness evaluation was conducted using the ASTM D5237-05 standard, with a blank test as a control, where the softness grade was 0, which means the hardest. The pure cotton plain fabric treated with a softener was used as a control, where the softness grade was 5, which means the softest.

[0062] Table 1 Performance test results

[0063] Test items Example 1 Example 2 Example 3 Softness 4 4 4.1 Transverse fracture (N / 5cm) 32 36 38 Longitudinal breaking strength (N / 5cm) 30 42 36 Transverse elongation at break 32% 30% 32% Longitudinal elongation at break 30% 30% 32%

[0064] It can be seen from Table 1 that the present invention enables the yarn strength of the high-count and high-density fabric to meet the requirements while having a sufficiently soft feel.

[0065] The above is a detailed introduction to the preparation method of a super-soft high-count and high-density fabric provided by the present application. Specific examples are used in this article to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea; at the same time, for general technicians in this field, according to the idea of ​​the present application, there will be changes in the specific implementation method and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A method for preparing ultra-soft high-count and high-density fabric, characterized in that: The following steps are involved: (1) Select 40S combed long-staple cotton yarn as the warp yarn; (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 9.5 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 180 MPa and the spinning speed is about 3000 m / min; obtaining an ultrafine denier polyester fiber having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fiber is used as weft yarn; the ultrafine denier polyester fiber has a single filament fineness of 0.4 dtex, a breaking strength of 4.7 cN / dtex, and an elongation at break of 42%; the arrangement of the pores on the cross section of the ultrafine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center; (3) The warp yarns are warped and sized in sequence before being drawn into the heddle and reeded; (4) Weaving: The warp and weft yarns are woven on a jet loom using plain weave, with a loom speed of 400r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively; (5) Air washing and softening treatment: The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air-washed in the Aile super soft finishing machine; specifically: the softening treatment temperature is 180°C and the treatment time is 2 minutes.

2. A method for preparing ultra-soft high-count and high-density fabric, characterized in that: The following steps are involved: (1) Select 80S combed long-staple cotton yarn as the warp yarn; (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 10 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 200 MPa and the spinning speed is about 4000 m / min; obtaining an ultrafine denier polyester fiber having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fiber is used as weft yarn; the ultrafine denier polyester fiber has a single filament fineness of 0.6 dtex, a breaking strength of 5.2 cN / dtex, and an elongation at break of 35%; the arrangement of the pores on the cross section of the ultrafine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center; (3) The warp yarns are warped and sized in sequence before being drawn into the heddle and reeded; (4) Weaving: The warp and weft yarns are woven on a jet loom using plain weave, with a loom speed of 450r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively; (5) Air washing and softening treatment: The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air washed in the Aile super soft finishing machine; specifically: the softening treatment temperature is 190°C and the treatment time is 1.5 minutes.

3. A method for preparing ultra-soft high-count and high-density fabric, characterized in that: The following steps are involved: (1) Select 60S combed long-staple cotton yarn as the warp yarn; (2) Making warp yarn: drying PET pellets and feeding them into a screw extruder to melt them, wherein the melting temperature of the PET pellets is about 285°C and the pressure of the screw extruder is 9.6 MPa; extruding the PET melt through a porous spinneret, wherein the pressure of the PET melt is 180 MPa and the spinning speed is about 3600 m / min; obtaining an ultrafine denier polyester fiber having regular hexagonal pores in the cross section, wherein the regular hexagonal pores are located near the outer circumference of the polyester fiber cross section, and the ultrafine denier polyester fiber is used as weft yarn; the ultrafine denier polyester fiber has a single filament fineness of 0.5 dtex, a breaking strength of 5.0 N / dtex, and an elongation at break of 36%; the arrangement of the pores on the cross section of the ultrafine denier polyester fiber is 1-2 circles with the center of the polyester fiber as the center; (3) The warp yarns are warped and sized in sequence before being drawn into the heddle and reeded; (4) Weaving: The warp and weft yarns are woven on a jet loom using plain weave, with a loom speed of 420r / min; the lower heddle height and opening amount are 161mm and 82mm, and the side support gasket is 4mm; the rear beam height is 115mm, and the front and rear positions are 6 grids; the warp stop frame height is 3 grids, and the front and rear positions are 15 grids; the opening time is 290°; the main jet timing is 86-160°; the weft storage timing is 80-202°; the weft yarn reaches 236-240°; the auxiliary jet timings of 01-08 are: 86-156°, 96-166°, 110-180°, 130-200°, 150-220°, 160-230°, 170-250°, and 190-300° respectively; (5) Air washing and softening treatment: The fabric is immersed in the foam formed by the foaming machine, which contains softener, and then the fabric is air washed in the Aile super soft finishing machine; specifically: the softening treatment temperature is 180°C and the treatment time is 1.6 minutes.

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