Roller shutter fabric with natural hemp grass style and preparation method thereof

Abstract

The invention discloses a roller shutter fabric with a natural hemp grass style and a preparation method thereof. The preparation method comprises the following steps: S1, adopting a warp-wise regular spaced hollow doup weaving method for base cloth; the warp yarns are selected from 300D lustrous twisted yarns; three-in-one fancy twisted yarns and fancy composite yarns are respectively selected for two adjacent weft yarns; s2, performing weft straightening and shaping treatment on the base cloth; s3, the base cloth is subjected to size dipping treatment, and the size evenly covers the two faces of the fabric in a padding mode; and S4, carrying out drying treatment on the fabric subjected to the dipping treatment. The roller shutter fabric closer to the natural hemp grass style is provided, meanwhile, the sun exposure performance, the mildew-proof performance, the waterproof performance and the like are remarkably improved, and the dual requirements of modern home decoration for attractiveness and practicability are met.

Description

Technical Field

[0001] The invention relates to a roller blind fabric, in particular to a roller blind fabric with natural hemp grass style and a preparation method thereof. Background Art

[0002] As people's demand for interior decoration materials becomes increasingly diversified, fabrics imitating natural materials are gradually favored by the market. The common imitation cotton fabrics and imitation linen fabrics on the market have the appearance and touch of cotton or linen by processing the yarn with a specific process. The production of this type of fabric is relatively mature, and the yarn processing process has been relatively standardized. However, these imitation cotton and imitation linen fabrics only imitate the characteristics of cotton or linen at the yarn level, and the overall texture style of the fabric does not have the characteristics of natural materials.

[0003] In contrast, the imitation hemp style fabric is not only processed on the yarn, but also requires the entire fabric to show a natural hemp texture style after weaving. This kind of imitation hemp style fabric should visually present a texture close to hand-woven, and have a certain rough and natural appearance, which puts forward higher requirements on the weaving process.

[0004] At present, there is no fabric on the market that can truly simulate the style of hemp grass. To weave a fabric that imitates the style of hemp grass, it is not only necessary to select the right yarn material, but also to use precise weaving methods to achieve complex texture effects. In particular, how to maintain the stability of the fabric structure while presenting an irregular but natural texture is a major challenge faced by this technical field.

[0005] Therefore, developing a fabric that imitates the style of hemp must not only have the natural appearance of hemp, but also solve the shortcomings of natural hemp in terms of sun fastness, mildew resistance and waterproofness, while being able to be mass-produced to ensure its cost-effectiveness, which has become a technical issue that urgently needs to be broken through. Summary of the invention

[0006] The purpose of the present invention is to provide a roller blind fabric with a natural hemp style and a preparation method thereof. The fabric not only has the natural appearance and texture of a hemp roller blind, but also has stronger weather resistance and longer service life than traditional natural hemp fabrics.

[0007] The technical solution adopted by the present invention to solve its technical problem is:

[0008] A method for preparing a roller blind fabric with a natural hemp style comprises the following steps:

[0009] S1. Weaving of base fabric

[0010] The base fabric is made of twisted heald weaving with regular intervals of hollowing in the warp direction;

[0011] The warp yarn is made of 300D glossy twisted yarn;

[0012] The two adjacent weft yarns are respectively made of three-in-one fancy twisted yarn and fancy composite yarn;

[0013] The three-in-one fancy twisted yarn is formed by three-in-one fancy twisting of 150D white silk, 150D irregular segment dyed silk and 8-count irregular slub yarn, and has a special fancy slub style;

[0014] The fancy composite yarn is made of 300D / FDY glossy colored yarn, 300D / FDY matte colored yarn and 300D / DTY glossy masterbatch yarn, which are mixed in a ratio of 1:1:4 and woven through a mesh-jointing machine; the style of this yarn is close to rough hemp, with different gloss, distinct layers and colors, and its texture is similar to rough paper.

[0015] S2, weft straightening and shaping process

[0016] The base fabric is shaped by an automatic weft shaping integrated equipment line, so that the warp and weft skew and weft arc after weft shaping are controlled within ≤0.5%;

[0017] S3, double-sided overall slurry dipping process

[0018] The base fabric after weft straightening and shaping is treated with slurry, and the slurry is evenly covered on both sides of the fabric by padding;

[0019] The slurry for the slurry treatment is prepared by mixing and stirring 35 to 40 parts of polyurethane emulsion, 15 to 20 parts of acrylic emulsion, 50 to 60 parts of deionized water and 0.5 to 0.8 parts of defoaming agent by weight;

[0020] S4, drying process

[0021] The fabric after slurry treatment is dried; the drying treatment is divided into three stages: pre-baking, baking, and cooling, with a total of 12 ovens; among which sections 1-4 are pre-baking sections, and the oven temperatures are 80°C / 100°C / 120 / 150°C respectively. The main function of this stage is to make most of the water in the foaming slurry evaporate evenly and control the coating surface to prevent conjunctivaeion;

[0022] Sections 5-8 are the baking sections, and the oven temperature is uniformly set at 180°C. At this stage, the impregnated slurry will undergo cross-linking and film-forming, and will also be relatively fully dried to avoid problems such as stickiness.

[0023] Sections 9 to 12 are gradient cooling sections, and the oven temperatures are 160℃ / 140℃ / 110℃ / 80℃ respectively. The purpose of this stage is to avoid excessive temperature difference between the inside and outside of the oven, which will cause thermal stress in the fabric structure or inside the yarn, thereby affecting the flatness and dimensional stability of the final product.

[0024] According to a further preferred technical solution, the warp yarns are alternately woven through four twisted heddle paths to form a hollow effect with an interval of 19 mm.

[0025] According to a further preferred technical solution, during the mesh weaving process, the air pressure of the mesh machine is set to 0.7 MPa and the vehicle speed is 50 m / min.

[0026] To further optimize the technical solution, in the automatic weft straightening and shaping integrated equipment line, the weft straightening equipment uses the German EL Lemmer intelligent weft straightening machine, and the weft straightening speed is set to 15-20 m / min; the shaping oven has 12 sections, of which sections 1 to 4 are pre-baking areas, and the temperatures are 80°C, 100°C, 120°C, and 140°C respectively; sections 5 to 12 are baking areas, and the oven temperature is uniformly set to 160°C.

[0027] A roller blind fabric with natural hemp style, characterized in that it is made by the above method.

[0028] The beneficial effects of the present invention are:

[0029] 1. Overall texture presentation: Unlike imitation cotton or imitation linen fabrics, imitation linen style fabrics achieve the overall texture effect after the fabric is completed through a specific weaving process, rather than just the processing of the yarn. The fabric simulates the rough and natural appearance of natural linen and has a texture close to hand-woven.

[0030] 2. Solve the limitations of the existing technology: There is no imitation hemp fabric on the market that can truly show the style of hemp. The present invention has made innovations in fabric weaving and material selection, overcoming the limitation that traditional fabrics are only imitated at the yarn level, and successfully developed imitation hemp fabric.

[0031] 3. Improve sunlight fastness: Natural hemp fabrics are prone to fading, yellowing and other problems after long-term exposure to the sun, while the imitation hemp fabric of the present invention uses high-performance masterbatch yarn, which greatly improves the sunlight fastness and keeps the color stable in a high temperature environment.

[0032] 4. Excellent mildew-proof and waterproof performance: Natural hemp fabrics are susceptible to moisture and mildew, while imitation hemp fabrics have good mildew-proof and waterproof properties through double-sided slurry dipping process, which is suitable for long-term use in a variety of environments and extends the service life of the product.

[0033] 5. Scalable production: The production process of natural hemp fabrics is complicated, and it is difficult to achieve large-scale production and the cost is high. Imitation hemp fabrics use standardized processes to ensure a stable supply of raw materials and the feasibility of mass production, greatly reducing production costs and having a high cost-effectiveness.

[0034] Through these technical advantages, the present invention not only provides a roller blind fabric that is closer to the style of natural hemp, but also significantly improves the performance in terms of sun exposure, mildew resistance, and waterproofness, thus meeting the dual needs of modern home decoration for aesthetics and practicality. DETAILED DESCRIPTION

[0035] The present invention is further described below.

[0036] The manufacturing method of a natural hemp-style roller blind fabric is mainly divided into the following steps, each of which is carefully designed to ensure that the final product has high cost performance, excellent light fastness, moisture resistance and environmental protection. The following are detailed process steps and explanations of each detail:

[0037] 1. Weaving of the main fabric

[0038] Methods and processes:

[0039] The main fabric is woven in this way, with four twisted heddle paths alternately woven to create a hollow effect with an interval of 19 mm. The twisted heddle weaving method makes the fabric structure stable, with a style similar to hand-woven, and increases the breathability and aesthetics of the fabric.

[0040] Two adjacent weft yarns are respectively selected from three-in-one fancy twisted yarn and fancy composite yarn.

[0041] The loom uses imported Dornier heavy-duty rapier loom, which guarantees the stability of weft insertion and weaving of coarse yarns.

[0042] Material selection:

[0043] Warp: 300D glossy twisted yarn is used to increase the firmness and glossiness of the fabric, making it closer to the effect of hand-woven.

[0044] Three-in-one fancy twisted yarn: It uses 150D white silk, 150D irregular segment dyed silk and 8 irregular bamboo knots. This combination forms a special fancy bamboo knot style, creating a natural hemp grass visual effect.

[0045] Fancy composite yarn: 1050D fancy segment-dyed composite yarn and 2400D masterbatch fancy composite yarn are mixed in a ratio of 1:1:4 and woven through a mesh-jointing machine to form a composite yarn with a sense of layering and distinct colors, with a rough texture similar to paper.

[0046] In the processing of fancy composite yarns, air pressure and machine speed are key factors affecting the final style effect and inherent mechanical properties of the composite yarn. Generally speaking, the best combination of air pressure and machine speed can be determined through experiments and observations to achieve the best processing effect and production efficiency.

[0047] Appropriate air pressure can form a tight entanglement between fibers, improve the network degree, and thus enhance the cohesion and overall strength of the fibers. If the air pressure is too low, the fibers are not fully entangled, which may lead to insufficient network degree and affect subsequent processing and performance; if the air pressure is too high, it may cause excessive entanglement or even breakage of the fibers, and increase equipment wear.

[0048] The speed determines the residence time of the fiber in the mesh machine, thus affecting the entanglement effect of the fiber. If the speed is too fast, the residence time of the fiber in the mesh machine is too short, which may lead to insufficient entanglement; if the speed is too slow, although the entanglement effect can be improved, it will reduce processing efficiency and increase production costs.

[0049] The present invention adopts orthogonal test optimization design to determine that the air pressure of the mesh-joining machine is set to 0.7MP and the vehicle speed is 50 meters per minute; the mesh density and entanglement effect of the composite yarn processed by mixed mesh-joining are optimal.

[0050] Advantages:

[0051] Multi-level visual effects: The combination of different yarns makes the fabric present rich colors and texture effects, enhancing the three-dimensional sense and decorativeness of the fabric.

[0052] Tight fabric structure: The twisted heddle weaving method ensures the tightness of the fabric, not loose, improves the durability and tear resistance of the fabric, and is very suitable for high-strength roller blinds.

[0053] 2. Weft straightening and shaping process

[0054] Process Description:

[0055] Weft shaping: Before sizing, weft shaping is an important step to ensure the flatness of the fabric surface and the consistency of the warp and weft directions. The control of this process is crucial to the effect of subsequent sizing.

[0056] Specific operations:

[0057] Equipment selection: automatic weft straightening and shaping integrated equipment line is adopted, and the weft straightening equipment is the German EL Leimer intelligent weft straightening machine.

[0058] Speed ​​and temperature control: The weft straightening speed is set at 15-20M / min; the shaping oven has 12 sections, of which sections 1-4 are pre-drying areas with temperatures of 80℃ / 100℃ / 120℃ / 140℃ respectively; sections 5-12 are baking areas with a uniform oven temperature of 160℃. This setting helps prevent the fabric from deforming or shrinking due to excessively high or low temperatures.

[0059] Curvature control: After weft straightening, the weft skew and weft arc in the warp and weft directions are controlled at ≤0.5% (i.e. 0.5% of the width of the fabric) to ensure the flatness and dimensional stability of the fabric.

[0060] Advantages:

[0061] Ensure the flatness and dimensional stability of the fabric: Through precise speed and temperature control, as well as careful management of the curvature, the fabric is ensured to be in the best condition before sizing, avoiding processing difficulties caused by unevenness or dimensional changes in subsequent processes.

[0062] 3. Double-sided overall slurry dipping process

[0063] Process steps:

[0064] Slurry preparation: The slurry for slurry treatment is prepared by mixing and stirring 35-40 parts of polyurethane emulsion, 15-20 parts of acrylic emulsion, 50-60 parts of deionized water and 0.5-0.8 parts of defoamer by weight. Polyurethane provides softness and wear resistance, and acrylic acid improves the hardness and waterproof performance of the fabric.

[0065] Padding process: The slurry is evenly coated on both sides of the fabric by padding, and then dried, shaped and rolled.

[0066] Specific operations:

[0067] Sizing: Through padding, the sizing liquid is evenly penetrated into the fabric fibers to ensure that the coating thickness of the fabric is uniform.

[0068] Advantages:

[0069] Improved durability and functionality: The combination of polyurethane and acrylic not only enhances the fabric's waterproofness and abrasion resistance, but also gives the fabric better sunlight fastness, making it suitable for environments exposed to sunlight for a long time.

[0070] Maintain a soft feel: Despite the sizing treatment, the fabric retains its softness, making it durable yet maintains a good feel, making it suitable for high-quality roller blinds.

[0071] 4. Drying process

[0072] Drying: During the drying process, the temperature and time are controlled to allow the water in the slurry to evaporate fully, and the polyurethane and acrylic components are evenly attached to the fiber surface to achieve a shaping effect.

[0073] The drying process is divided into three stages: pre-baking, baking and cooling, with a total of 12 ovens. Sections 1 to 4 are pre-baking sections, with oven temperatures of 80°C / 100°C / 120°C / 150°C respectively. The main function of this stage is to make most of the water in the foaming slurry evaporate evenly and control the coating surface to prevent film formation.

[0074] Sections 5-8 are the baking sections, and the oven temperature is uniformly set at 180°C. At this stage, the impregnated slurry will undergo cross-linking and film-forming, and will also be relatively fully dried to avoid problems such as stickiness.

[0075] Sections 9 to 12 are gradient cooling sections, and the oven temperatures are 160℃ / 140℃ / 110℃ / 80℃ respectively. The purpose of this stage is to avoid excessive temperature difference between the inside and outside of the oven, which will cause thermal stress in the fabric structure or inside the yarn, thereby affecting the flatness and dimensional stability of the final product.

[0076] Finally, the fabric is rolled into semi-finished roller blinds, ready for subsequent finished product processing.

[0077] 5. Comparison of appearance and texture with natural hemp fabric

[0078] Purpose of the experiment: To verify whether the appearance and texture of the imitation hemp style roller blind fabric can achieve the same effect as the natural hemp fabric.

[0079] Experimental Materials:

[0080] 1. Hemp-like style roller blind fabric (fabric sample of the present invention)

[0081] 2. Natural hemp fabric (common natural hemp roller blind fabric samples on the market)

[0082] Experimental methods:

[0083] 1. Appearance comparison

[0084] Comparison items: Observe and evaluate the color, texture, gloss and other appearance characteristics of the fabric.

[0085] Comparison method: The two fabrics were photographed and video recorded under the same lighting conditions (natural light and artificial light), and the weaving texture details of the fabrics were observed using a high-resolution microscope to evaluate the similarity in appearance between the two.

[0086] Data recording: Use image processing software to analyze the texture image of the fabric and calculate parameters such as texture uniformity, texture interval size, color distribution, etc.

[0087] 2. Texture contrast

[0088] Comparison items: Evaluate the feel, softness, roughness and thickness of the fabric.

[0089] Comparison method:

[0090] Feel test: Invite 10 volunteers to give texture scores (1-10 points, 10 being the closest to the texture of natural hemp) by touching the two fabric samples without knowing the origin of the fabrics.

[0091] Softness and hardness test: Use a professional softness tester to test the softness and hardness of the two fabrics in the warp and weft directions respectively, and record their respective warp and weft softness and hardness data (such as radial extension length / weft extension length, in CM).

[0092] Roughness test: Use a surface roughness meter to measure the surface roughness of the two fabrics in microns (μm).

[0093] Thickness test: Use a thickness gauge to accurately measure the thickness of the fabric in millimeters (mm).

[0094] 3. Comparative experimental data

[0095] Appearance comparison data:

[0096] Color analysis: record the RGB values ​​of two fabrics and compare the color similarity.

[0097] Texture detail: Microscope images are used to measure the number of texture lines per square centimeter and the depth of the texture.

[0098] Gloss test: Use a gloss meter to measure the reflectivity of the two fabrics in gloss units (GU).

[0099] Texture comparison data:

[0100] Hand feel rating: The ratings of 10 volunteers were recorded and the average value was calculated.

[0101] Hardness: Record the measurement results of the hardness tester.

[0102] Roughness: Record the measurement data of the surface roughness meter.

[0103] Thickness: Record the results of the thickness gauge.

[0104] Experimental data comparison:

[0105]

[0106] Experimental comparison conclusion:

[0107] The above comparative experimental data show that the appearance and texture of the imitation hemp style roller blind fabric are very similar to those of the natural hemp fabric. The appearance parameters such as color, number of textures, texture depth, glossiness, etc. are very close, and the hand feel rating and texture data (softness, roughness, thickness) are also very close. The subjective ratings of the volunteers show that the hand feel of the two fabrics is similar and difficult to distinguish.

[0108] Therefore, the conclusion drawn from the experiment is that the imitation hemp style roller blind fabric designed by the present invention is very close to the natural hemp fabric in appearance and texture, can effectively simulate the natural style of natural hemp, and has better durability.

[0109] 6. Comparison of weather resistance with natural hemp fabric

[0110] Purpose

[0111] Through comparative experiments, the technical advantages of the imitation hemp style roller blind fabric of the present invention over traditional natural hemp fabric in terms of sunlight fastness, mildew resistance and waterproofness are verified.

[0112] Experimental Materials

[0113] 1. Sample of imitation hemp style roller blind fabric (fabric of the present invention)

[0114] 2. Natural hemp fabric samples (traditional natural hemp fabrics available on the market)

[0115] Experimental methods

[0116] 1. Light fastness test

[0117] Test standard: According to ISO 105-B02 "Textiles - Tests for colour fastness - Colour fastness to artificial light sources".

[0118] step:

[0119] · Cut the imitation hemp style roller blind fabric and the natural hemp fabric into samples of the same size (such as 10cm x10cm).

[0120] · Fix the sample in a light fastness tester and expose it to a standard artificial light source (such as a xenon lamp light source) to simulate sunlight exposure conditions.

[0121] · Expose continuously for 48 hours, observe the color change of the sample every 8 hours, and record the color fastness change of the sample.

[0122] · Compare the color fastness changes of the two samples after the test and rate them according to the gray scale (gray scale).

[0123] 2. Anti-mildew test

[0124] Test standard: Based on ASTM G21 "Material Antifungal Test Standard".

[0125] step:

[0126] · Cut the imitation hemp style roller blind fabric and the natural hemp fabric into samples of the same size.

[0127] ·The sample is placed on a culture medium containing mold spores (such as Czapek-Dox agar medium) and cultured in an environment of 95% RH and 28° C. for 7 days.

[0128] · Observe and record the growth of mold on the surface of the sample, and evaluate the mold resistance of the sample according to the percentage of mold growth area.

[0129] 3. Waterproof test

[0130] Test standard: According to AATCC 22 "Textile Waterproofness Test: Initial Immersion Method".

[0131] step:

[0132] · Cut the imitation hemp style roller blind fabric and the natural hemp fabric into samples of the same size (such as 10cm x10cm).

[0133] · Use a water spray tester to spray water onto the sample surface at a certain pressure for 1 minute to simulate rainfall or a humid environment.

[0134] · Observe the state of water droplets on the sample surface, and record the number of water droplets formed on the sample surface and the wetting condition of the sample.

[0135] · The water resistance of the samples was evaluated according to the AATCC water resistance rating standard (0-100).

[0136] Experimental data comparison:

[0137]

[0138] Experimental comparison conclusion:

[0139] Through comparative experiments, it will be shown that the imitation hemp style roller blind fabric is superior to the traditional natural hemp fabric in terms of sunlight fastness, mildew resistance and water resistance, thereby verifying the technical advantages of the present invention and proving its durability and performance superiority in practical applications.

[0140] Summarize

[0141] Through the above detailed process steps and material selection, the imitation hemp grass roller blind fabric of the present invention is not only close to the natural hemp grass style in appearance, but also has high cost performance, excellent durability and environmental protection characteristics. This fabric is very suitable for home and commercial curtain decoration that requires both decorative effect and durability, and can meet the user's multiple needs for aesthetics, practicality and environmental protection.

Claims

1. A method for preparing a roller blind fabric with a natural hemp style, characterized in that: The steps include: S1. Weaving of base fabric The base fabric is made of twisted heald weaving with regular intervals of hollowing in the warp direction; The warp yarn is made of 300D glossy twisted yarn; The two adjacent weft yarns are respectively made of three-in-one fancy twisted yarn and fancy composite yarn; The three-in-one fancy twisted yarn is formed by three-in-one fancy twisting of 150D white silk, 150D irregular segment dyed silk and 8-count irregular slub yarn, and has a special fancy slub style; The fancy composite yarn is made of 300D / FDY glossy colored yarn, 300D / FDY matte colored yarn and 300D / DTY glossy masterbatch yarn, which are mixed in a ratio of 1:1:4 and woven through a mesh-joining machine; S2, weft straightening and shaping process The base fabric is shaped by an automatic weft shaping integrated equipment line, so that the warp and weft skew and weft arc after weft shaping are controlled within ≤0.5%; S3, double-sided overall slurry dipping process The base fabric after weft straightening and shaping is treated with slurry, and the slurry is evenly covered on both sides of the fabric by padding; The slurry for the slurry treatment is prepared by mixing and stirring 35 to 40 parts of polyurethane emulsion, 15 to 20 parts of acrylic emulsion, 50 to 60 parts of deionized water and 0.5 to 0.8 parts of defoaming agent by weight; S4, drying process The fabric after sizing treatment is dried; the drying treatment is divided into three stages: pre-baking, baking and cooling, with a total of 12 ovens; among them, sections 1-4 are pre-baking sections, and the oven temperatures are 80°C / 100°C / 120 / 150°C respectively; sections 5-8 are baking sections, and the oven temperature is uniformly 180°C; sections 9-12 are gradient cooling sections, and the oven temperatures are 160°C / 140°C / 110°C / 80°C respectively.

2. A method for preparing a roller blind fabric with a natural hemp style as claimed in claim 1, characterized in that: The warp yarns are woven alternately through four twisted heddle paths to form a hollow effect with an interval of 19 mm.

3. The method for preparing a roller blind fabric with natural hemp style as claimed in claim 1, characterized in that: During the mesh weaving process, the air pressure of the mesh machine was set to 0.7 MPa and the speed was 50 m / min.

4. The method for preparing a roller blind fabric with natural hemp style as claimed in claim 1, characterized in that: In the automatic weft straightening and shaping integrated equipment line, the weft straightening equipment uses the German EL Leimer intelligent weft straightening machine, and the weft straightening speed is set to 15-20 m / min; the shaping oven has 12 sections, of which sections 1 to 4 are pre-baking areas, and the temperatures are 80°C, 100°C, 120°C, and 140°C respectively; sections 5 to 12 are baking areas, and the oven temperature is uniformly set to 160°C.

5. A roller blind fabric with natural hemp style, characterized in that: The method is made by any one of claims 1 to 4.

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