Ultrahigh-count high-density down-proof fabric and manufacturing method

Abstract

The invention relates to an ultrahigh-count high-density down-proof fabric and a manufacturing method, and belongs to the technical field of spinning. The manufacturing method comprises the steps that combed cotton yarn with the nominal linear density being 4.83 + / -0.1 tex and the single yarn breaking strength being 118 + / -10 cN is adopted as a warp raw material, superfine special yarn is adopted as a weft raw material, eight warp face satin weave is adopted as a fabric weave, the warp density is designed to be 1575 pieces / 10 CM-1800 pieces / 10 CM (400 pieces / inch-457 pieces / inch), and the weft density is designed to be 984 pieces / 10 CM-1378 pieces / 10 CM (250 pieces / inch-350 pieces / inch); warping is conducted; sizing is conducted; weaving on a machine; and dyeing and finishing. The invention further discloses the ultrahigh-count and high-density down-proof fabric obtained by the manufacturing method. The ultra-high density of the fabric is increased, the yarn superfine count of the fabric is increased, the fabric texture tightness of the fabric is reduced, the after-finishing calendaring process is combined, and the fabric which is high in comfort level, soft in hand feeling and good in down-proof performance is manufactured; the novel down-proof fabric is breathable, comfortable and good in glossiness.

Description

Technical Field

[0001] The invention relates to an ultra-high count and high-density down-proof fabric and a manufacturing method thereof, and belongs to the technical field of textiles. Background Art

[0002] As a textile, there must be pores between the yarns of the fabric. The smaller the pores, the better the anti-down effect. However, in reality, the pores cannot be too small. The size of the pores is related to the breathability of the fabric. If the breathability is poor, the sweat produced in the quilt cannot be discharged, and the quilt becomes damp, which not only affects the comfort, but also breeds bacteria and other microorganisms, affecting the health of the user. Therefore, the down quilt fabric must have a good anti-down effect and a certain degree of breathability. This poses a great challenge to the production process.

[0003] There are currently three main methods to improve down quilt fabrics: increasing fabric density, calendering and coating.

[0004] Increase fabric density and fabric tightness: The higher the fabric count, the finer the yarn, and the denser the woven cloth. Common ones are 100, 80, 60, 40, etc. However, the denser the better. Too much density will make the fabric thinner, which will affect the anti-down effect. The fabric is generally woven with plain, twill, and 5-piece satin structures. The fabric is tight and feels hard. It will make a rustling sound during use, affecting consumers' sleep quality and touch.

[0005] Calendering process: under certain conditions, the fabric yarn is flattened, so that the surface of the fabric becomes smooth and clean, the gaps are reduced, and the anti-down effect is achieved. The disadvantage is that it cannot be washed with water. After washing several times, the fabric fibers will return to their original state and lose the anti-down effect.

[0006] Coating process: refers to coating a layer of polymer compounds on the fabric, such as waterproof coating on jackets. It completely blocks the pores between the fabrics and has a good anti-down drilling effect. The disadvantage is poor air permeability and low comfort.

[0007] In view of the shortcomings of the existing technology, the fabric has good anti-down effect and good breathability, while being soft to the touch and noiseless, overcoming the problem that traditional down quilt fabrics are rough and noisy, which has become a difficulty in the industry. Currently, there is no mature process to produce anti-down fabrics that meet such requirements.

[0008] Our company previously published a patent application with application publication number CN115652499A. The patent name is a pure cotton extra-high warp density fabric and its processing method. By borrowing our company's previous technical conditions, we redesigned the yarn, density and post-processing process, and obtained a brand-new anti-down fabric and technical process in the field of anti-down fabric technology. Summary of the invention

[0009] In order to solve the above problems, the present invention discloses an ultra-high count and high-density down-proof fabric and a manufacturing method thereof, and the specific technical scheme thereof is as follows:

[0010] A method for making an ultra-high count and high-density down-proof fabric comprises the following steps:

[0011] Step 1 Yarn design: The warp yarn is made of combed cotton yarn with a nominal linear density of 4.83±0.1tex and a single yarn breaking strength of 118±10cN. The weft yarn is made of ultra-fine yarn with a nominal linear density of 4.83±0.1tex, 4.21±0.1tex, 3.69±0.1tex, 3.28±0.1tex, or 2.95±0.1tex.

[0012] Step 2 Fabric structure: The fabric structure uses eight warp satin structures.

[0013] Step 3: Warp and weft density: The warp density is designed to be 1575 strands / 10CM to 1800 strands / CM, i.e. 400 strands / inch to 457 strands / inch, and the weft density is designed to be 984 strands / 10CM to 1378 strands / CM, i.e. 250 strands / inch to 350 strands / inch;

[0014] Step 4: warping: warping the warp yarns using a high-speed micro-tension adjustment warping machine;

[0015] Step 5 Sizing step: Only the warp yarn is sized by the sizing machine, and then dried. The sizing machine is equipped with three parallel sizing tanks, each of which adopts the form of double dipping and double pressing. During the sizing process, the yarn passes through the three sizing tanks side by side, and the number of yarns sized in each sizing tank is one third of the total number of yarns.

[0016] Step 6 Weaving on the machine: The air jet loom is equipped with 16 to 22 groups of auxiliary nozzles, each group of 2 auxiliary nozzles is controlled by the same control valve, and the auxiliary nozzles are arranged at equal intervals, with a spacing of 8 to 12 cm;

[0017] Step 7 Dyeing and finishing step: singeing, desizing, degreasing, mercerizing, softening, calendering, shrinkage and qualitative treatment of the woven fabric.

[0018] Furthermore, the slurry for sizing the yarn in step 5 is a mixture of a solid part and a liquid part, wherein the solid part accounts for 15±1% by weight and the liquid part is water; the solid part includes starch, PVA1799, PVA205, solid propylene and wax flakes, and the weight ratio of the solid part is starch: PVA1799: PVA205: solid propylene: wax flakes = 100: 75: 70: 10: 4.

[0019] Furthermore, when the yarn is sized in step 5, the slurry temperature is 80 to 90 degrees.

[0020] Furthermore, the weaving process in step 6 is as follows: back beam 80, depth 1, warp stop frame height 4, depth 2 grids, the back beam height, depth, warp stop frame height and depth values ​​are the values ​​on the back beam and warp stop frame position adjustment scale on the jet loom, opening time 280 degrees, machine speed 380 rpm, weft insertion time 100-190 degrees, air pressure auxiliary pressure 0.32 kpa main pressure 0.18 kpa, and solenoid valve opening time 90-170 degrees.

[0021] Furthermore, the mercerization treatment in step 7 is to ensure the gloss of the fabric surface, and the fabric that has been treated before calendering is calendered using a calendering machine, the line pressure at the calendering point is 150-220N / mm, the temperature is 100-150°C, the speed is 18-25m / min, and the calendering is repeated three times.

[0022] The ultra-high count and high-density down-proof fabric is made by the above-mentioned method for making the ultra-high count and high-density down-proof fabric.

[0023] The beneficial effects of the present invention are:

[0024] The invention increases the fabric to ultra-high density, improves the ultra-fine count of the fabric yarn, reduces the fabric tissue tightness, and combines the post-finishing calendering process to produce a new type of anti-down fabric with high comfort, soft fabric feel, good anti-down property, breathability, comfort and good gloss. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is the eight warp satin weave diagram described in the present invention. DETAILED DESCRIPTION

[0026] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0027] The key innovations of the down-proof fabric of the present invention include increasing the fabric's ultra-high density, improving the fabric's extra-fine yarn count, reducing the fabric's weave tightness, and combining it with a post-finishing calendering process to produce a super down-proof fabric with high comfort, good fabric feel, and good air permeability.

[0028] The applicant's unit previously disclosed CN115652499A patent for a pure cotton ultra-high warp density fabric and its processing method. Based on the previous patent technology, the yarn, density and post-processing process were redesigned to obtain a brand-new anti-down fabric and technical process in the field of anti-down fabric technology. The process is described in detail below:

[0029] 1. Yarn design: The warp yarn of the present invention adopts combed cotton yarn with a nominal linear density of 4.83±0.1tex and a single yarn breaking strength of 118±10cN. The weft yarn raw materials respectively adopt nominal linear densities of 4.83±0.1tex, 4.21±0.1tex, 3.69±0.1tex, 3.28±0.1tex or 2.95±0.1tex. The selected weft yarns are all ultra-fine special yarns. The finer the yarn, the more difficult the spinning process is, and the lower the strength is, and it is easy to be blown off and shut down during the compressed air weft insertion process.

[0030] 2. Fabric structure: The fabric of the present invention is mainly used for down quilts. The fabric structure adopts eight-warp satin structure. The fabric structure of down fabrics on the market is basically satin, plain and twill with less than five warps. These structures have high tightness to improve the down-proof effect. The eight-warp satin structure adopted by the present invention is shown in Figure 1 , reducing the tightness from the organizational structure is obviously contrary to the organizational structure of existing anti-down fabrics. This is the uniqueness of the present invention. The organizational structure of the present invention is sparse, the warp and weft density are closely interwoven, and the post-finishing calendering is added to improve the anti-down effect.

[0031] 3. Warp and weft density: The warp density is designed to be 1575 roots / 10CM-1800 roots / 10CM, i.e. 400 roots / inch-457 roots / inch, and the weft density is designed to be 984 roots / 10CM-1378 roots / 10CM, i.e. 250 roots / inch-350 roots / inch.

[0032] 4. Warping: Use high-speed micro-tension adjustment warping machine to arrange the warp threads.

[0033] 5. Sizing step: In view of the fact that the combed cotton yarn used in the present invention is relatively dense and not easy to be sized, in order to ensure the penetration and coating of the sizing agent during sizing and the flattening of the hairiness after sizing, the sizing machine of the embodiment of the present invention is equipped with three side-by-side sizing tanks, each of which adopts the form of double dipping and double pressing. Therefore, during the sizing treatment, the yarn passes through the three sizing tanks side by side, and the number of yarns sized in each sizing tank is one-third of the total number of yarns. In addition, in order to ensure the sizing effect, improve the strength of the warp yarn after sizing, and ensure the elongation and wear resistance after sizing, the present invention is specially equipped with sizing. The sizing is a mixture of a solid part and a liquid part, wherein the solid part accounts for 15±1% by weight and the liquid part is water. The solid part is mixed with 50kg of starch, 37.5kg of PVA1799, 35kg of PVA205, 5kg of solid propylene, and 2kg of wax flakes, that is, the solid part is composed of starch, PVA1799, PVA205, solid propylene and wax flakes in a weight ratio of 100:75:70:10:4. When sizing, the slurry temperature is 80-90 degrees.

[0034] 6. Weaving machine: The present invention has many warps and high warp density, and the weft insertion is easy to cause obstruction of warp yarn hairiness. In addition, the weft yarn strength is low. For this reason, the air jet loom of the present invention adopts a high-density auxiliary nozzle configuration. The air jet loom is equipped with 16 to 22 groups of auxiliary nozzles, and each group of 2 auxiliary nozzles is controlled by the same control valve. The auxiliary nozzles are arranged at equal intervals, with a spacing of 8 to 12 cm. In order to solve the frequent breakage of warp yarns and the easy breakage of weft yarns during the process, the specific machine process is as follows: rear beam 80, depth 1, warp stop frame height 4 depth 2 grids. Opening time 280 degrees, vehicle speed 380 rpm, weft insertion time 100-190 degrees, air pressure auxiliary pressure 0.32kpa main pressure 0.18kpa, solenoid valve opening time 90-170 degrees. Here, the rear beam height, depth, warp stop frame height and depth values ​​are the values ​​on the rear beam and warp stop frame position adjustment scale on the air jet loom.

[0035] 7. Dyeing and finishing steps: singeing, desizing, degreasing, mercerizing, softening, calendering, shrinkage and qualitative treatment of the woven grey fabric. Conventional anti-down treatment generally does not include the mercerizing process. Mercerizing can improve the gloss of the cloth surface. The general anti-down post-treatment does not have a mercerizing process, and mainly relies on calendering. After mercerizing, the hairiness is reduced, the yarn becomes thinner and the space becomes larger, which is not conducive to anti-down. This is the uniqueness of this patented anti-down fabric. High count and high density plus calendering treatment improves the anti-down effect.

[0036] The above steps are used to design a new type of anti-down fabric that is soft to the touch, has good anti-down property, is breathable and comfortable, and has good glossiness.

[0037] Specification Wind speed before washing Wind speed after washing 3.69±0.1tex 19 22 3.47±0.1tex 15 22 4.21±0.1tex 20 24 4.83±0.1tex 16 23

[0038] It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as those generally understood by those skilled in the art to which this application belongs. It should also be understood that terms such as those defined in common dictionaries should be understood to have meanings consistent with the meanings in the context of the prior art, and will not be interpreted with idealized or overly formal meanings unless defined as herein.

[0039] With the above-mentioned ideal embodiments of the present invention as inspiration, through the above-mentioned description content, relevant personnel can make various changes and modifications without departing from the scope of the technical idea of ​​the present invention.

Claims

1. A method for making ultra-high count and high-density down-proof fabric, characterized in that: The following steps are involved: Step 1 Yarn design: The warp yarn is made of combed cotton yarn with a nominal linear density of 4.83±0.1tex and a single yarn breaking strength of 118±10cN. The weft yarn is made of ultra-fine yarn with a nominal linear density of 4.83±0.1tex, 4.21±0.1tex, 3.69±0.1tex, 3.28±0.1tex, or 2.95±0.1tex. Step 2 Fabric structure: The fabric structure uses eight warp satin structures. Step 3: Warp and weft density: The warp density is designed to be 1575 strands / 10CM to 1800 strands / CM, i.e. 400 strands / inch to 457 strands / inch, and the weft density is designed to be 984 strands / 10CM to 1378 strands / CM, i.e. 250 strands / inch to 350 strands / inch; Step 4: warping: warping the warp yarns using a high-speed micro-tension adjustment warping machine; Step 5 Sizing step: Only the warp yarn is sized by the sizing machine, and then dried. The sizing machine is equipped with three parallel sizing tanks, each of which adopts the form of double dipping and double pressing. During the sizing process, the yarn passes through the three sizing tanks side by side, and the number of yarns sized in each sizing tank is one third of the total number of yarns. Step 6 Weaving on the machine: The air jet loom is equipped with 16 to 22 groups of auxiliary nozzles, each group of 2 auxiliary nozzles is controlled by the same control valve, and the auxiliary nozzles are arranged at equal intervals, with a spacing of 8 to 12 cm; Step 7: Dyeing and finishing: singeing, desizing, degreasing, mercerizing, softening, calendering, shrinkage and qualitative treatment of the woven fabric.

2. The method for making the ultra-high count and high-density down-proof fabric according to claim 1, characterized in that: The slurry for sizing the yarn in step 5 is a mixture of a solid part and a liquid part, wherein the solid part accounts for 15±1% by weight and the liquid part is water; the solid part includes starch, PVA1799, PVA205, solid propylene and wax flakes, and the weight ratio of the solid part is starch: PVA1799: PVA205: solid propylene: wax flakes = 100: 75: 70: 10:

4.

3. The method for making the ultra-high count and high-density down-proof fabric according to claim 1, characterized in that: When the yarn is sized in step 5, the slurry temperature is 80 to 90 degrees.

4. The method for making the ultra-high count and high-density down-proof fabric according to claim 1, characterized in that: The weaving process in step 6 is as follows: back beam 80, depth 1, warp stop frame height 4, depth 2 grids, the back beam height, depth, warp stop frame height and depth values ​​are the values ​​on the back beam and warp stop frame position adjustment scale on the air jet loom, opening time 280 degrees, machine speed 380 rpm, weft insertion time 100-190 degrees, air pressure auxiliary pressure 0.32 kpa main pressure 0.18 kpa, and solenoid valve opening time 90-170 degrees.

5. The method for making the ultra-high count and high-density down-proof fabric according to claim 1, characterized in that: The mercerization treatment in step 7 is to ensure the gloss of the cloth surface. The fabric treated before calendering is calendered using a calendering machine. The line pressure at the calendering point is 150-220N / mm, the temperature is 100-150°C, the speed is 18-25m / min, and the calendering is repeated three times.

6. Ultra-high count and high-density anti-down fabric made by the method for making ultra-high count and high-density anti-down fabric according to any one of claims 1 to 5.

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