Machine-washable comfortable elastic fluff fabric and preparation method thereof

Abstract

The invention relates to a machine-washable comfortable elastic fluff fabric and a preparation method thereof, high-count fluff, polyether ester fiber and regenerated Sorona elastic fiber are adopted as raw materials, and through scientific proportioning of the three raw materials, the fabric is endowed with extremely soft hand feeling, lasting shape retention and easy dyeability of normal-temperature and normal-pressure boiling dyeing; the fabric is bright in color, excellent in color fastness, good in moisture absorption and sweat releasing performance and comfortable in stretching resilience; the hand feeling effect of 30% of fluff can exceed that of 100% of worsted fluff, an airflow washing and shrinking combined machine is adopted for production, and fullness and fineness of the fluff are guaranteed. The combination of the high-count fluff, the polyether ester fiber and the regenerated Sorona elastic fiber can realize one-bath normal-temperature and normal-pressure dyeing, the high-count fluff is not subjected to scale stripping treatment, the energy consumption and pollution emission are effectively reduced, the social significance of energy conservation and environmental protection is huge, and a novel woolen fabric product with an ecological environmental protection concept is provided.

Description

Technical Field

[0001] The present invention belongs to the technical field of the production of woolen fabrics, and particularly relates to a machine-washable comfortable elastic villous fabric and a preparation method thereof. Background Art

[0002] Although there are various innovations in the patterns, textures, and applications of woolen fabrics, there are still three problems that are difficult to overcome.

[0003] First, due to the scales on the villi, woolen products cannot be machine-washable and can only be dry-cleaned. Although some can achieve machine washability through chemical descaling of wool, the villi lose their natural crimp and natural elasticity, and the felting property of the villi is lost. The fabric lacks plump and delicate villi, making high-end natural villi fibers zombified. In the prior art, in order to achieve machine washability of villous fabrics, chemical descaling treatment is required for the villi. Chemical descaling causes the villi to lose their scales, greatly reducing the natural crimp and natural elasticity of the villi, losing the felting property of the villi, lacking plump and delicate villi on the fabric, reducing the warmth retention of the villi, and making high-end villi lose their natural soft luster and soft and waxy handfeel. Chemical descaling also damages and reduces the strength of the villi. At the same time, during the chemical descaling process, a large amount of chemical fiber auxiliaries are used, and repeated water washing is required after descaling, consuming a large amount of water resources; after rinsing, a dryer is also required to dry the villi, consuming a large amount of heat energy. The descaling treatment of the villi is equivalent to the cost of one dyeing, increasing the production cost and also causing a large amount of energy consumption and emission pollution.

[0004] Second, for lightweight villi and polyester (polyester) blended worsted woolen fabrics, in actual production, traditional fiber separate dyeing, then mixing and blending spinning of the two fibers, and then high-temperature setting finishing are carried out, resulting in high energy consumption, complex processes, and long production cycles. In the prior art, for villi-polyester blended fabrics, generally, villi and polyester fibers are dyed separately, and after the two fibers are dyed, they are mixed and spun together. Conventional polyester (polyester) is mainly dyed with high-temperature high-pressure disperse dyes. The high pollution emissions and high energy consumption during the dyeing process have always been environmental problems that every woolen textile production enterprise has to face. At the same time, due to the high-temperature dyeing and setting characteristics required by polyester (polyester) fibers, villi-polyester (polyester) blended yarns and grey fabrics cannot be subjected to yarn dyeing and grey fabric dyeing, otherwise, high temperatures will cause great damage and loss to the villi. This also leads to a long production cycle of villi-polyester blended fabrics, unable to meet the rapid and flexible adjustment needs of the market.

[0005] Thirdly, the elasticity of woven woolen fabrics is poor and lacks sufficient elasticity for human comfort. To increase the elasticity of the fabric, spandex is generally added, and core-spun spinning or ply spinning of spandex yarn is carried out. On the one hand, this makes the production complex, and on the other hand, during the fabric finishing process, the spandex also needs to be secondarily shaped, resulting in high energy consumption in production. In addition, the elasticity of knitted worsted woolen fabrics is too large, resulting in poor drapability, stiffness, and shape retention of the clothing, and the application range is also very limited.

[0006] To solve the deficiencies in the prior art, the present invention proposes a new type of machine-washable comfortable elastic plush fabric and its preparation method. Summary of the Invention

[0007] To solve the problems existing in the prior art, the present invention proposes a machine-washable comfortable elastic plush fabric and its preparation method from the aspects of easy care, machine washability, comfort, energy conservation, environmental protection, and a sense of luxury, and proposes a product that is more convenient to care for, warmer, more comfortable, and more luxurious. First, the present invention selects high-count plush, polyether ester fiber, and recycled Sorona elastic fiber for co-spinning. Without chemically scaly treating the plush and without destroying the plush scales, the machine washability and easy care of the plush polyester fabric and its products are realized. Second, the present invention does not use spandex, reduces the complex spinning process, and realizes the comfortable elasticity of the plush polyester fabric and its products on the basis of finishing the fabric at room temperature. Third, on the basis of energy conservation, environmental protection, and low carbon emissions, the present invention realizes the dyeing of plush polyester blended yarns and grey fabrics, diversifies the fabric patterns, and meets the fast return demand of the market.

[0008] In the first aspect, the present invention provides a preparation method for a machine-washable comfortable elastic plush fabric, including the following steps: Step (1), raw material selection. The fabric raw materials include 20%-40% high-count plush, 30%-40% polyether ester fiber, and 30%-40% recycled Sorona elastic fiber; Step (2), spinning. The semi-combed compact spinning process is adopted, the spinning count is 60-80 Nm / 2, and the single yarn twist coefficient is 120-150; Step (3), weaving. The 2 / 2 right twill weave is used, the warp and weft yarn counts are 50-80 Nm / 2, the warp density on the loom is 200-300 / 10 cm, the weft density in the weft direction is 200-250 picks / 10 cm, the width of the grey fabric is 150-200 cm, and the single weight of the grey fabric is 250-300 g / m; Step (4), piece dyeing. The fabric is piece-dyed by using a one-bath dyeing process; Step (5), finishing. The piece-dyed fabric is post-finished by an air-flow washing and shrinking combined machine.

[0009] Further, in step (2), the length of the fluff is 30 - 50 mm, the length of the polyether ester fiber is 38 mm, and the length of the Sorona elastic fiber is 38 mm.

[0010] Further, in step (4), piece dyeing is carried out using reactive dyes, and the dyeing temperature is 98 - 100 °C.

[0011] Further, in step (5), the water temperature of the air flow washing and shrinking combined machine is set to 40 - 50 °C, and the time is 40 - 60 minutes.

[0012] Further, in step (5), after the fabric is treated by the air flow washing and shrinking combined machine, it is dried and shaped once, and the drying and shaping temperature is 140 - 180 °C.

[0013] Further, in step (5), during the drying and shaping process, the fabric feeding overfeed is 10 - 20%, and the width of the fabric on the shaping machine is 150 - 200 cm.

[0014] Further, in step (5), after the shaping treatment, it also includes the treatment processes of shearing, decating, and preshrinking.

[0015] Further, the fineness of the high - count fluff is not higher than 17.5 microns.

[0016] In the second aspect, the present invention also provides a machine - washable comfortable elastic fluff fabric, which is prepared by the aforementioned preparation method. The fabric includes high - count fluff, polyether ester fiber length, and Sorona elastic fiber. The high - count fluff is not subjected to scaly treatment; the fabric does not include spandex fiber.

[0017] Compared with the prior art, the present invention has at least the following beneficial effects: 1. The present invention uses high - count fluff, polyether ester fiber, and regenerated Sorona elastic fiber as raw materials. Through the scientific ratio of the above three raw materials: 20% - 40% of fluff fiber, 30% - 40% of polyether ester fiber, and 30 - 40% of elastic fiber, it endows the fabric with an extremely soft hand feeling, lasting shape retention, easy dyeability at normal temperature and pressure boiling dyeing, bright colors, excellent color fastness, good moisture absorption and sweat discharge performance, comfortable stretch recovery performance, chlorine / ultraviolet resistance, stain resistance, and wrinkle resistance, etc.; with a fluff content of 30%, it can exceed the hand feeling effect of 100% worsted fluff. Without using the traditional milling method and adopting the air flow washing and shrinking combined machine for production, it ensures the fullness and fineness of the fluff; 2. The present invention selects high-count fluff, polyether ester fiber, and regenerated Sorona elastic fiber for co-spinning, which not only realizes the easy care, machine washability, comfort, and high-class feeling of fluff products. At the same time, the combination of high-count fluff, polyether ester fiber, and regenerated Sorona elastic fiber can achieve one-bath normal-temperature and normal-pressure dyeing, and no scaly treatment is carried out on the high-count fluff, effectively reducing energy consumption and pollution emissions. It has great social significance in energy conservation and environmental protection and is a new type of woolen fabric product that conforms to the concept of ecological environmental protection. Specific implementation method To make the technical problems solved by the present invention, the technical solutions adopted, and the achieved technical effects clearer, the present invention will be further described in detail below with reference to the embodiments. It can be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. In addition, it should be noted that for the convenience of description, only the parts related to the present invention are shown in the embodiments rather than all the content.

[0019] In terms of raw material selection, the scientific raw material ratio is the basis for ensuring the machine washability, comfortable elasticity, energy-saving production, and high-class feeling of the fabric.

[0020] The fabric raw materials of the present invention include 20%-40% high-count fluff, 30%-40% polyether ester fiber, and 30%-40% regenerated Sorona elastic fiber. Such a raw material ratio not only ensures that the product has true fluff quality but also has machine washability and comfortable elasticity. At the same time, such a raw material ratio can reduce the damage of blended fibers, achieve one-bath dyeing, reduce costs, improve production efficiency, and meet the flexible adjustment needs of the market during yarn dyeing and grey fabric dyeing.

[0021] For high-count fluff, the fineness selected in the present invention is fine wool not higher than 17.5 microns and with a length of 32-45 mm.

[0022] For polyether ester fiber, the polyether ester fiber used in the present invention adds "hydrophilic molecules - & - flexible chain segments" to the polyester macromolecule. It has the characteristics of low-temperature and normal-pressure dyeing, environmental protection and energy saving, low-temperature setting, self-hydrophilicity, high moisture regain, low modulus, anti-pilling, full-color system dyeing, and anti-static.

[0023] The regenerated Sorona elastic fiber is a polyester bicomponent composite fiber, which is characterized by good elasticity, permanent crimpability, excellent fluffiness, smooth hand feeling, not easy to relax, and has good chemical stability and dyeability.

[0024] During the yarn preparation process, the present invention adopts the semi-combed siro compact spinning process.

[0025] The present invention uses fluff with a length of 32 - 45 mm, rather than the traditional worsted top with a length of over 80 mm; both the polyether ester fiber and the regenerated Sorona elastic fiber are staple fibers with a length of 38 mm. The spinning process takes a different approach and adopts a semi-combed compact spinning process route. This can not only facilitate the carding of fibers but also ensure that the spinning count reaches 60 - 80 Nm / 2, facilitating the realization of the lightness and thinness of the fabric.

[0026] Compact spinning can keep the hairiness of the yarn within a controllable range, enabling the yarn to be woven smoothly and making the fabric have plump and delicate fluff on the surface and a soft handfeel after finishing. It is found through actual measurement that the content of 30% fluff in this product has a more sufficient fluff feeling than that of a 100% fluff worsted fabric, thus tapping the true value of the fluff. Cherishing the use of rare animal fibers is also a good way to be environmentally friendly and reduce carbon emissions.

[0027] During the yarn preparation process, the high-count fluff has a length of 32 - 45 mm, the polyether ester fiber has a length of 38 mm, and the Sorona elastic fiber has a length of 38 mm. According to the length of the raw materials, the spinning adopts a semi-combed compact spinning process route. The spinning count is 60 - 80 Nm / 2, the single yarn twist coefficient is 120 - 150, preferably 135; the hairiness of the yarn reaches a controllable range for smooth weaving, and after the woven fabric is finished, the fabric has plump and delicate fluff on the surface and a soft handfeel.

[0028] During the grey fabric weaving process, the fabric weave adopts a 2 / 2 right twill weave, the warp and weft yarn counts are 50 - 80 Nm / 2, preferably 60 Nm / 2; the warp density on the loom is 200 - 300 per 10 cm, preferably 231 per 10 cm; the weft density in the weft direction is 200 - 250 per 10 cm, preferably 206 per 10 cm; the width of the grey fabric is 150 - 200 cm, preferably 169 cm; the single weight of the grey fabric is 250 - 300 grams per meter, preferably 279 grams per meter.

[0029] The present invention adopts a relaxed finishing technology, and the grey fabric is dyed by a one-bath method. Practical examination experience shows that temperature is the primary factor among the three factors causing fluff damage (the three factors for fluff damage are high temperature, acid-base, and carding breakage). In actual production, the fluff is basically dyed with reactive dyes, and the dyeing temperature is 98 - 100 °C. The dyeing temperature of the polyether ester fiber and the regenerated Sorona elastic fiber is also 95 - 100 °C. The coincidence of the three temperatures avoids the high-temperature damage of the fluff and ensures the true natural handfeel of the fluff.

[0030] One-bath dyeing is adopted, which is efficient, energy-saving and easy to operate. At the same time, it is an inevitable process for relaxed finishing. At the same time, in order to ensure that 30% of the fluff can exceed the hand feeling effect of worsted 100% fluff, the traditional milling method is not adopted, and an air-flow washing and shrinking combined machine is used in production to ensure the fullness and fineness of the fluff. When shaping the fabric, the heat shrinkage function of elastic fibers should be fully utilized, and the overfeed and the width of the fabric on the shaping machine should be well controlled, so that the elasticity of the fabric can reach sufficient comfort and drapability.

[0031] The following provides three specific embodiments.

[0032] Example 1 A method for preparing a machine-washable comfortable elastic fluff fabric includes the following steps: Step (1), raw material selection. The fabric raw materials include 20% high-count fluff, 50% polyether ester fiber, and 30% recycled Sorona elastic fiber; Step (2), spinning. The fluff length is 32 - 45 mm, the polyether ester fiber length is 38 mm, and the Sorona elastic fiber length is 38 mm. According to the raw material length, a semi-combed compact spinning process route is determined for spinning. The spinning count is 60 - 80 Nm / 2, the single yarn twist coefficient is 135, and the yarn hairiness reaches a controllable range, enabling smooth weaving. After the fabric is finished, the surface fluff is full and delicate, and the hand feeling is soft. Step (3), weaving. A 2 / 2 right twill weave is adopted, the warp and weft yarn counts are 60 Nm / 2, the warp density on the loom is 231 threads / 10 cm, the weft density in the weft direction is 206 threads / 10 cm, the width of the grey fabric is 169 cm, and the single weight of the grey fabric is 279 grams / meter; Step (4), piece dyeing. The fabric is subjected to piece dyeing treatment using a one-bath dyeing process; Step (5), finishing. The piece-dyed fabric is subjected to post-finishing through an air-flow washing and shrinking combined machine. The water temperature of the washing and shrinking combined machine is 45°C, and the time is 60 minutes; it is dried and shaped at 160°C for the first time, the fabric feeding overfeed is 15%, and the width of the fabric on the shaping machine is 150 cm; subsequent shearing, decating, and pre-shrinking are carried out to finally obtain the finished product.

[0033] Example 2 A method for preparing a machine-washable comfortable elastic fluff fabric includes the following steps: Step (1), raw material selection. The fabric raw materials include 30% high-count fluff, 40% polyether ester fiber, and 30% recycled Sorona elastic fiber; Step (2): Spinning. The length of the fluff is 32 - 45 mm, the length of the polyether ester fiber is 38 mm, and the length of the Sorona elastic fiber is 38 mm. According to the length of the raw materials, the semi-combed compact spinning process route is determined for spinning. The spinning count is 60 - 80 Nm / 2, the single yarn twist coefficient is 135, the hairiness of the yarn reaches the controllable range, and weaving is carried out smoothly. After the fabric is finished, the fluff on the fabric surface is plump and delicate, and the hand feeling is soft.; Step (3): Weaving. The 2 / 2 right twill weave is adopted, the warp and weft yarn count is 60 Nm / 2, the warp density on the loom is 231 ends per 10 cm, the weft density in the weft direction is 206 picks per 10 cm, the width of the grey cloth is 169 cm, and the single weight of the grey cloth is 279 grams per meter; Step (4): Piece dyeing. The fabric is subjected to piece dyeing treatment by using a one-bath dyeing process; Step (5): Finishing. The piece-dyed fabric is subjected to post-finishing by an air-flow washing and shrinking combined machine. The water temperature of the washing and shrinking combined machine is 45 °C and the time is 60 minutes; drying and shaping are carried out at 160 °C for the first time, the fabric feeding overfeed is 15%, and the width of the fabric on the shaping machine is 150 cm; subsequent shearing, decating, and pre-shrinking are carried out to finally obtain the finished product.

[0034] Example 3 A method for preparing a machine-washable comfortable elastic fluff fabric, comprising the following steps: Step (1): Raw material selection. The fabric raw materials include 40% high-count fluff, 30% polyether ester fiber, and 30% regenerated Sorona elastic fiber; Step (2): Spinning. The length of the fluff is 32 - 45 mm, the length of the polyether ester fiber is 38 mm, and the length of the Sorona elastic fiber is 38 mm. According to the length of the raw materials, the semi-combed compact spinning process route is determined for spinning. The spinning count is 60 - 80 Nm / 2, the single yarn twist coefficient is 135, the hairiness of the yarn reaches the controllable range, and weaving is carried out smoothly. After the fabric is finished, the fluff on the fabric surface is plump and delicate, and the hand feeling is soft.; Step (3): Weaving. The 2 / 2 right twill weave is adopted, the warp and weft yarn count is 60 Nm / 2, the warp density on the loom is 231 ends per 10 cm, the weft density in the weft direction is 206 picks per 10 cm, the width of the grey cloth is 169 cm, and the single weight of the grey cloth is 279 grams per meter; Step (4): Piece dyeing. The fabric is subjected to piece dyeing treatment by using a one-bath dyeing process; Step (5): Finishing. The piece-dyed fabric is subjected to post-finishing by an air-flow washing and shrinking combined machine. The water temperature of the washing and shrinking combined machine is 45 °C and the time is 60 minutes; drying and shaping are carried out at 160 °C for the first time, the fabric feeding overfeed is 15%, and the width of the fabric on the shaping machine is 150 cm; subsequent shearing, decating, and pre-shrinking are carried out to finally obtain the finished product.

[0035] Under the condition that the spinning method, yarn count, twist, weaving tightness, and finishing conditions are the same, the experimental data of the present invention: Example 1: 20% high-count fluff (length 32 - 45 mm), 50% polyether ester fiber, 30% recycled Sorona elastic fiber. The finished fabric has a suede surface that is not delicate and plump enough. After machine washing, the fabric size remains unchanged, and it has good elastic comfort.

[0036] Example 2: 30% high-count fluff (length 32 - 45 mm), 40% polyether ester fiber, 30% recycled Sorona elastic fiber. The finished fabric has an ideal suede surface, showing delicate and plumpness. After machine washing, the fluff does not get entangled, the fabric size remains unchanged, and it has good elastic comfort.

[0037] Example 3: 40% high-count fluff (length 32 - 45 mm), 30% polyether ester fiber, 30% recycled Sorona elastic fiber. The finished fabric has a plump suede appearance, but there is a slight entanglement between the fluff. After machine washing, the fabric size also remains unchanged, and it has good elastic comfort.

[0038] The above technical solutions use high-count fluff, polyether ester fiber, and recycled Sorona elastic fiber as raw materials. Through the scientific ratio of the above three raw materials: 20% - 40% fluff fiber, 30% - 40% polyether ester fiber, and 30% - 40% elastic fiber, the fabric is given an extremely soft handfeel, lasting shape retention, easy dyeability at normal temperature and pressure by boiling dyeing, bright colors, excellent color fastness, good moisture absorption and sweat discharge performance, comfortable stretch recovery, chlorine / ultraviolet resistance, stain resistance, and wrinkle resistance, etc.; with a 30% fluff content, it can exceed the handfeel effect of 100% worsted fluff. Instead of using the traditional milling method, it is produced by an air flow washing and shrinking combined machine, ensuring the plumpness and delicacy of the fluff.

[0039] By selecting the co-spinning of high-count fluff, polyether ester fiber, and recycled Sorona elastic fiber, not only the fluff products are easy to care for, machine washable, comfortable, and have a high-class feeling. At the same time, the combination of high-count fluff, polyether ester fiber, and recycled Sorona elastic fiber can achieve one-bath normal temperature and pressure dyeing, and no scaly treatment is carried out on the high-count fluff, effectively reducing energy consumption and pollution emissions. It has great social significance in energy conservation and environmental protection and is a new type of woolen fabric product that conforms to the concept of ecological environmental protection.

[0040] The above are only the preferred embodiments of the present invention, and do not impose any formal or substantial limitations on the present invention. It should be noted that for those of ordinary skill in the art, without departing from the present invention, several improvements and supplements can still be made, and these improvements and supplements should also be regarded as the protection scope of the present invention. Any equivalent changes such as slight modifications, decorations, and evolutions made by those skilled in the art who are familiar with this specialty without departing from the spirit and scope of the present invention by using the technical content disclosed above are equivalent embodiments of the present invention; at the same time, any equivalent changes, modifications, and evolutions made to the above embodiments based on the substantial technology of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A method for preparing a machine washable comfortable elastic fluff fabric, characterized in that: The steps include: Step (1), raw material selection, the fabric raw materials include 20%-40% high-count fluff, 30%-40% polyether ester fiber, and 30%-40% recycled Sorona elastic fiber; Step (2), spinning, using a semi-combed compact spinning process, with a spinning count of 60-80 Nm / 2 and a single yarn twist coefficient of 120-150; Step (3), weaving, 2 / 2 right twill weave, warp and weft yarn count 50-80 Nm / 2, warp density 200-300 / 10 cm on the loom, weft density 200-250 yarns / 10 cm in the weft direction, grey fabric width 150-200 cm, grey fabric single weight 250-300 g / m; Step (4), piece dyeing, using a one-bath dyeing process to piece dye the fabric; Step (5), finishing, finishing the piece-dyed fabric by an airflow washing and shrinking combined machine.

2. The method for preparing the machine washable comfortable elastic fleece fabric according to claim 1, characterized in that: In step (2), the length of the fluff is 30-50 mm, the length of the polyetherester fiber is 38 mm, and the length of the Sorona elastic fiber is 38 mm.

3. The method for preparing the machine washable comfortable elastic fluff fabric according to claim 1, characterized in that: In step (4), reactive dyes are used for piece dyeing at a temperature of 98-100°C.

4. The method for preparing the machine washable comfortable elastic fleece fabric according to claim 1, characterized in that: In step (5), the water temperature of the airflow washing and shrinking machine is set to 40-50°C and the time is 40-60 minutes.

5. The method for preparing machine washable comfortable elastic fleece fabric according to claim 1, characterized in that: In step (5), after the fabric is treated by the airflow washing and shrinking machine, it is dried and shaped at a temperature of 140-180°C.

6. The method for preparing the machine washable comfortable elastic fleece fabric according to claim 5, characterized in that: In step (5), during the drying and shaping process, the cloth is overfed by 10-20%, and the width of the shaping machine is 150-200 cm.

7. The method for preparing the machine washable comfortable elastic fleece fabric according to claim 6, characterized in that: In step (5), after the shaping treatment, the wool is further subjected to the treatment steps of shearing, decatizing and pre-shrinking.

8. The method for preparing a machine washable comfortable elastic fleece fabric according to any one of claims 1 to 7, characterized in that: The fineness of high-count fluff is no higher than 17.5 microns.

9. A machine washable comfortable elastic fleece fabric, characterized in that: The method is described in any one of claims 1 to 8.

10. The machine washable comfortable elastic fleece fabric according to claim 9, characterized in that: The fabric includes high-count fluff, polyether ester fiber length, and Sorona elastic fiber, and the high-count fluff is not subjected to descaling treatment; the fabric does not include spandex fiber.