High-strength cotton rattan manufacturing process

Abstract

The invention discloses a high-strength cotton rattan manufacturing process which comprises the following steps: dyeing cotton fibers for 20-60 minutes at the temperature of 40-80 DEG C, controlling the pH value of dye liquor to be 6.5-8.5, drying for 15-30 minutes at the temperature of 50-70 DEG C after dyeing, and controlling the humidity to be less than or equal to 30% RH (Relative Humidity). 3-10 cotton fibers and at least one polyester fiber are arranged in parallel to form a fiber bundle, the distance is controlled to be within 0.1 mm, the fiber bundle passes through a gluing device at the speed of 2-5 m / min, the glue solution with the viscosity of 800-1500 cps is coated, and the coating weight is 5-15 g / m < 2 >. Then compounding is conducted under the pressure of 0.2-0.8 MPa, a gradient heating technology is adopted for heat setting, finally, the rattan with the specific size is obtained through slitting, and an after-finishing procedure can be conducted. According to the technology, through reasonable fiber combination and a unique process, the tensile strength of the rattan is larger than or equal to 25 MPa, the bending fatigue life is larger than or equal to 5000 times, and the rattan has the advantages of being stable in performance, environmentally friendly, sustainable, good in processability and the like and is widely applied to the fields of furniture weaving, handicraft manufacturing and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of rattan production, and specifically refers to a manufacturing process for high-strength cotton rattan. The cotton rattan produced by this process can be widely used in furniture weaving, handicraft production, packaging decoration and other fields, providing a high-performance and high-quality rattan material for related industries. Background Art

[0002] In the fields of furniture weaving, handicraft production, etc., rattan is a commonly used material. Traditional rattan mainly comes from natural rattan plants, such as Calamus tetradactylus, Daemonorops margaritae, etc. However, natural rattan has some obvious limitations in the process of use.

[0003] Firstly, the growth cycle of natural rattan is relatively long, generally taking several years or even decades to reach the harvestable standard. With the continuous increase in the market demand for rattan, over-harvesting has led to the increasing scarcity of natural rattan resources, and the ecological environment has also been damaged to a certain extent. This makes the supply of natural rattan unstable, and the price has been rising continuously, increasing the production cost of related enterprises.

[0004] Secondly, there are certain differences in the physical properties of natural rattan. Due to different growth environments and conditions, different batches of natural rattan may have large fluctuations in strength, flexibility, etc. This brings great difficulties to quality control in the production process and is difficult to ensure the consistency and stability of products. For example, in the process of furniture weaving, if the strength of the rattan is inconsistent, it may cause damage to some parts of the woven furniture during use, affecting the service life and aesthetics of the product.

[0005] In addition, natural rattan is easily attacked by pests and diseases, and also requires specific environmental conditions during storage and transportation. Otherwise, it is easy to mildew and deteriorate, reducing the quality and usability of the rattan. Moreover, the processing performance of natural rattan is relatively poor. When performing processing treatments such as dyeing and shaping, complex processes and a long time are often required, resulting in low production efficiency.

[0006] To solve these problems, people have begun to try to develop artificial rattan. Although some artificial rattans on the market have solved the problems of resource shortage and some performance issues to a certain extent, they still cannot fully meet the actual needs in terms of strength, flexibility and appearance texture. Therefore, it is of great practical significance to develop a manufacturing process for high-strength, stable-performance and environmentally friendly cotton rattan. Summary of the Invention

[0007] The present invention aims to solve the above technical problems and provides a manufacturing process for high-strength cotton rattan.

[0008] To solve the above technical problems, the technical solution provided by the present invention is as follows:

[0009] 1. A manufacturing process for high-strength cotton rattan, characterized by comprising the following steps:

[0010] S1: Arrange 3 - 10 cotton fibers and at least 1 polyester fiber in parallel to form a fiber bundle, and control the parallel spacing between the fibers within 0.1 mm;

[0011] S2: Pass the fiber bundle through a gluing device at a speed of 2 - 5 m / min, apply a glue solution with a viscosity of 800 - 1500 cps for coating, and the coating amount is 5 - 15 g / m 2 ;

[0012] S3: Compress the glue-coated fiber bundle under a pressure of 0.2 - 0.8 MPa, and then perform heat setting at a temperature of 80 - 100 °C for 5 - 15 minutes;

[0013] S4: Cut the product after heat setting into flat rattan strips with a width of 1.8 - 3.5 mm and a thickness of 0.5 - 1.2 mm.

[0014] Further, before step S1, it further includes:

[0015] Dye the cotton fibers at 40 - 80 °C for 20 - 60 minutes, and control the pH value of the dyeing solution at 6.5 - 8.5;

[0016] Dry the dyed fibers in an environment at 50 - 70 °C for 15 - 30 minutes, and control the environmental humidity ≤ 30% RH.

[0017] Further, the glue used in the gluing device in step S2 has a solid content of 40% - 60%, and the bonding strength of the glue at 25 °C is 1.8 - 3.2 kN / m.

[0018] Further, the heat setting in step S3 adopts a gradient heating process:

[0019] The first stage: Raise the temperature from room temperature to 60 °C at a rate of 2 °C / min and keep it for 5 minutes;

[0020] The second stage: Raise the temperature to 80 - 100 °C at a rate of 1 °C / min and keep it for 5 - 15 minutes.

[0021] Further, the width tolerance of the finished product in step S4 is ±0.15 mm, the thickness tolerance is ±0.1 mm, the tensile strength ≥ 25 MPa, and the bending fatigue life ≥ 5000 times.

[0022] Further, it further includes a post-treatment process:

[0023] Wind up using a constant-tension winding device with a tension of 0.8 - 1.5 N.

[0024] The advantages of the present invention compared with the prior art are as follows:

[0025] 1. The cotton rattan produced by the present invention has high tensile strength and bending fatigue life. Through reasonable fiber combination and optimized production process, the tensile strength of the rattan is ≥25 MPa, and the bending fatigue life is ≥5000 times, which can meet the requirements for the strength of rattan in fields such as furniture weaving and handicraft production, improving the durability and service life of the products.

[0026] 2. Due to the use of artificial materials and standardized production processes, the problem of large differences in the physical properties of natural rattan is overcome. The cotton rattan produced by this process has good consistency and stability in terms of strength, flexibility, etc., which is convenient for quality control during the production process and ensures the quality of the products.

[0027] 3. Compared with natural rattan, the production process of the cotton rattan of the present invention does not rely on natural rattan resources, reducing the damage to the ecological environment. Cotton fibers and polyester fibers are both common artificial materials, with wide sources, and the production process is relatively environmentally friendly, meeting the requirements of sustainable development.

[0028] 4. This cotton rattan has better performance in processing treatments such as dyeing and shaping. The pretreatment step can evenly dye the cotton fibers, and the color is long-lasting. During subsequent weaving and production processes, the rattan is easy to process, which can improve production efficiency and reduce production costs.

[0029] 5. The presence of cotton fibers endows the rattan with a soft and natural appearance texture, similar to natural rattan, which can meet the aesthetic requirements of consumers for products. At the same time, by controlling the production process parameters, the appearance characteristics such as the color and luster of the rattan can be adjusted, increasing the diversity and market competitiveness of the products. Brief Description of the Drawings

[0030] Figure 1 It is a schematic structural diagram of the first embodiment of the present invention.

[0031] As shown in the figure: 1. Horizontal cotton thread; 2. Vertical cotton thread; 3. First inclined cotton thread; 4. Second inclined cotton thread. Detailed Embodiment

[0032] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the following further details the present invention in conjunction with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0033] I. Working Principle of the Present Invention:

[0034] Dyeing and Drying Pretreatment

[0035] Before step S1, the cotton fibers are dyed at 40 - 80°C for 20 - 60 minutes, and the pH value of the dyeing solution is controlled at 6.5 - 8.5; after dyeing, the fibers are dried at 50 - 70°C for 15 - 30 minutes, and the environmental humidity is controlled at ≤30% RH.

[0036] Fiber bundle arrangement step S1

[0037] Arrange 3 - 10 cotton fibers and at least 1 polyester fiber in parallel to form a fiber bundle, and the parallel spacing between the fibers is controlled within 0.1 mm.

[0038] Adhesive solution coating step S2

[0039] Pass the fiber bundle through the gluing device at a speed of 2 - 5 m / min, apply an adhesive solution with a viscosity of 800 - 1500 cps for coating, and the coating amount is 5 - 15 g / m 2 . The solid content of the glue used in the gluing device is 40% - 60%, and the bonding strength of the glue at 25°C is 1.8 - 3.2 kN / m.

[0040] Lamination and heat setting step S3

[0041] Laminating the fiber bundle coated with glue under a pressure of 0.2 - 0.8 MPa, and then performing heat setting at a temperature of 80 - 100°C for 5 - 15 minutes. The heat setting adopts a gradient heating process: in the first stage, the temperature is raised from room temperature to 60°C at a rate of 2°C / min and held for 5 minutes; in the second stage, the temperature is raised to 80 - 100°C at a rate of 1°C / min and held for 5 - 15 minutes.

[0042] Slitting step S4

[0043] Slit the shaped product into flat rattan strips with a width of 1.8 - 3.5 mm and a thickness of 0.5 - 1.2 mm. The width tolerance of the finished product is ±0.15 mm, the thickness tolerance is ±0.1 mm, the tensile strength is ≥25 MPa, and the flexural fatigue life is ≥5000 times.

[0044] Post - finishing process

[0045] Use a constant - tension winding device with a tension of 0.8 - 1.5 N for winding.

[0046] Cotton fibers have the advantages of being soft, breathable, and having good hygroscopicity, but their strength is relatively low. Polyester fibers have the characteristics of high strength, high modulus, and wear resistance. Arranging cotton fibers and polyester fibers in parallel to form a fiber bundle gives full play to the advantages of both fibers. Cotton fibers endow the rattan with a good hand feeling and natural texture, while polyester fibers improve the overall strength and wear resistance of the rattan, enabling the rattan to have higher physical properties while ensuring comfort.

[0047] The glue with a specific viscosity and coating amount is applied by the gluing device, so that the fibers in the fiber bundle can be firmly bonded together. The solid content and bonding strength of the glue are crucial to the performance of rattan. The appropriate solid content can ensure that the glue forms sufficient bonding force after drying, while the appropriate bonding strength ensures that the fibers are tightly bonded and not easy to separate. Compounding under pressure further enhances the bonding force between the fibers, making the structure of the rattan more compact and stable.

[0048] Heat setting is one of the key steps in the process. The gradient heating process allows the fiber and glue to gradually adapt and react at different temperature stages, avoiding fiber deformation or uneven glue bonding due to rapid temperature changes. In the first stage, the temperature is raised to 60°C and maintained for a certain period of time, which is conducive to the initial curing of the glue and the initial stabilization of the fiber. In the second stage, the temperature is slowly raised to 80-100°C and maintained for a period of time to fully cure the glue and further adjust and fix the molecular structure of the fiber, thereby improving the dimensional stability and strength of the rattan.

[0049] The slitting process processes the shaped product into flat rattan strips of specific width and thickness to meet the needs of different application scenarios. The width and thickness tolerances of the finished product are strictly controlled to ensure the dimensional accuracy and consistency of the rattan strips. The constant tension winding device in the finishing process can keep the rattan strips in uniform tension during the winding process to avoid looseness or knotting.

[0050] 2. Implementation Method:

[0051] Example 1

[0052] 1. Dyeing and drying pretreatment

[0053] Cotton fibers were selected and placed in a dye vat, the dye liquor temperature was controlled at 60°C, the pH value of the dye liquor was adjusted to 7.5, and the dyeing time was 40 minutes. After dyeing, the fibers were transferred to a drying room, the temperature of the drying room was set at 60°C, the ambient humidity was controlled at 25% RH, and the drying time was 20 minutes.

[0054] 2. Fiber bundle arrangement

[0055] Five pretreated cotton fibers and two polyester fibers are arranged in parallel, and a special arrangement device is used to control the parallel spacing between the fibers to 0.1 mm to form a fiber bundle.

[0056] 3. Glue coating

[0057] A glue with a solid content of 50% and a bonding strength of 2.5 kN / m at 25°C was selected, and its viscosity was adjusted to 1200 cps. The fiber bundle passed through the gluing device at a speed of 3 m / min, and the glue coating amount was controlled to 10 g / m 2 .

[0058] 4. Lamination and Heat Setting

[0059] Put the fiber bundles after gluing into the lamination equipment and apply a pressure of 0.5 MPa for lamination. Heat setting adopts a gradient heating process: in the first stage, heat from room temperature to 60 °C at a rate of 2 °C / min and hold for 5 minutes; in the second stage, heat to 90 °C at a rate of 1 °C / min and hold for 10 minutes.

[0060] 5. Slitting

[0061] Use a slitting equipment to slit the shaped product into flat rattans with a width of 2.5 mm and a thickness of 0.8 mm. Strictly control the slitting accuracy so that the width tolerance of the finished product is controlled within ±0.15 mm and the thickness tolerance is controlled within ±0.1 mm.

[0062] 6. Post-treatment Process

[0063] Wind the rattans with a constant-tension winding device with a tension of 1.2 N to ensure uniform tension during the winding process.

[0064] 7. Weaving the Finished Product:

[0065] Weaving by the Horizontal Weaving Unit

[0066] The horizontal weaving unit includes at least one horizontal cotton thread 1. In this embodiment, two horizontal cotton threads are closely connected to form a group of horizontal cotton thread groups. Arrange multiple groups of horizontal cotton thread groups in parallel, and set a fixed interval between adjacent groups of horizontal cotton thread groups, and the interval distance is 8 mm. During the weaving process, use a weaving tool to arrange and fix the horizontal cotton threads in sequence to ensure close connection between adjacent two horizontal cotton threads and form a neat horizontal weaving structure.

[0067] Weaving by the Vertical Weaving Unit

[0068] The vertical weaving unit includes at least one vertical cotton thread 2. Similarly, two vertical cotton threads are closely connected to form a group of vertical cotton thread groups. Arrange multiple groups of vertical cotton thread groups in parallel, and the fixed interval between adjacent groups of vertical cotton thread groups is also 8 mm. Weave the vertical cotton threads and the horizontal cotton threads crosswise to form a square grid structure, and the side length of the square grid structure is 10 mm.

[0069] Weaving the X-shaped Reinforcement Structure

[0070] The X-shaped reinforcement structure is formed by the intersection of the first inclined cotton thread 3 and the second inclined cotton thread 4 at the weaving node. The first inclined cotton thread 3 crosses above the intersection point at an angle of +45°, and the second inclined cotton thread 4 crosses below the intersection point at an angle of -45°. During weaving, insert the first inclined cotton thread and the second inclined cotton thread into the square grid structure according to a certain rule, so that the diagonal length of the X-shaped reinforcement structure is 30% longer than the grid side length, that is, the diagonal length is 13 mm, thereby forming an octagonal hollow pattern.

[0071] Example 2

[0072] 1. Dyeing and drying pretreatment

[0073] The cotton fiber was dyed at 40°C for 60 minutes, and the pH value of the dye solution was 6.5. After dyeing, the fiber was dried at 50°C for 30 minutes, and the ambient humidity was controlled at 30% RH.

[0074] 2. Fiber bundle arrangement

[0075] Three cotton fibers and one polyester fiber are arranged in parallel with a spacing of 0.1 mm between the fibers to form a fiber bundle.

[0076] 3. Glue coating

[0077] The solid content of the glue is 40%, the bonding strength is 1.8kN / m at 25°C, and the viscosity is adjusted to 800cps. The fiber bundle passes through the gluing device at a speed of 2m / min, and the coating amount is 5g / m 2 .

[0078] 4. Composite and heat setting

[0079] The coated fiber bundles were compounded under a pressure of 0.2 MPa. In the first stage of heat setting, the temperature was raised from room temperature to 60°C at a rate of 2°C / min and maintained for 5 minutes; in the second stage, the temperature was raised to 80°C at a rate of 1°C / min and maintained for 15 minutes.

[0080] 5. Cutting

[0081] Cut into flat rattan strips with a width of 1.8mm and a thickness of 0.5mm, and control the width tolerance of the finished product to ±0.15mm and the thickness tolerance to ±0.1mm.

[0082] 6. Finishing process

[0083] The film is wound using a constant tension winding device with a tension of 0.8N.

[0084] 7. Prepare the finished product in the same manner as in Example 1.

[0085] Example 3

[0086] 1. Dyeing and drying pretreatment

[0087] The cotton fiber was dyed at 80°C for 20 minutes, and the pH value of the dye solution was 8.5. After dyeing, the fiber was dried at 70°C for 15 minutes, and the ambient humidity was controlled at 20% RH.

[0088] 2. Fiber bundle arrangement

[0089] Arrange 7 cotton fibers and 3 polyester fibers in parallel with a spacing of 0.1 mm between the fibers to form a fiber bundle.

[0090] 3. Glue Coating

[0091] The solid content of the glue is 60%, the bonding strength is 3.2 kN / m at 25°C, and the viscosity is adjusted to 1500 cps. The fiber bundle passes through the gluing device at a speed of 5 m / min, and the coating amount is 15 g / m 2 .

[0092] 4. Laminating and Heat Setting

[0093] The glued fiber bundle is laminated under a pressure of 0.8 MPa. In the first stage of heat setting, it is heated from room temperature to 60°C at a rate of 2°C / min and held for 5 minutes; in the second stage, it is heated to 100°C at a rate of 1°C / min and held for 5 minutes.

[0094] 5. Slitting

[0095] It is slit into flat rattan strips with a width of 3.5 mm and a thickness of 1.2 mm. The width tolerance of the finished product is controlled at ±0.15 mm, and the thickness tolerance is ±0.1 mm.

[0096] 6. Post-treatment Process

[0097] It is wound up by a constant-tension winding device with a tension of 1.5 N.

[0098] 7. Weaving the finished product, the method is the same as that in Example 1.

[0099] The performance of the cotton rattan produced in the above three examples was tested, and the test results are as follows:

[0100]

[0101] It can be seen from the test results that the manufacturing process of the high-strength cotton rattan of the present invention can produce rattan with high strength, good dimensional accuracy and flexural fatigue performance. The rattan performance of different embodiments meets the design requirements. By adjusting the process parameters, cotton rattan with different performances and specifications can be produced according to actual needs to adapt to different application scenarios.

[0102] The present invention and its implementation manners have been described above. Such description is not restrictive. What is shown in the drawings is only one of the implementation manners of the present invention, and the actual structure is not limited thereto. All in all, if those of ordinary skill in the art are inspired by it and design similar structural manners and embodiments without creative efforts without departing from the spirit of the present invention, they shall fall within the protection scope of the present invention.

Claims

1. A manufacturing process for high-strength cotton rattan, characterized in that: The following steps are involved: S1: 3-10 cotton fibers and at least one polyester fiber are arranged in parallel to form a fiber bundle, and the parallel spacing between the fibers is controlled within 0.1 mm; S2: Pass the fiber bundle through the gluing device at a speed of 2 - 5 m / min, apply a glue solution with a viscosity of 800 - 1500 cps for coating, and the coating amount is 5 - 15 g / m 2 ; S3: Compounding the coated fiber bundle under a pressure of 0.2-0.8 MPa, and then heat setting at a temperature of 80-100° C. for 5-15 minutes; S4: Cut the shaped product into flat rattan strips with a width of 1.8-3.5 mm and a thickness of 0.5-1.2 mm.

2. The manufacturing process of a high-strength cotton rattan according to claim 1, wherein: The step S1 also includes: Cotton fiber is dyed at 40-80℃ for 20-60 minutes, and the pH value of the dye solution is controlled at 6.5-8.5; After dyeing, the fiber is dried at 50-70°C for 15-30 minutes, and the ambient humidity is controlled to be ≤30%RH.

3. The manufacturing process of a high-strength cotton rattan according to claim 1, characterized in that: The solid content of the glue used by the gluing device in step S2 is 40%-60%, and the bonding strength of the glue at 25° C. is 1.8-3.2 kN / m.

4. A manufacturing process for high-strength cotton rattan according to claim 1, characterized in that: In step S3, the heat setting adopts a gradient heating process: The first stage: heating from room temperature to 60°C at a rate of 2°C / min and maintaining for 5 minutes; The second stage: increase the temperature to 80-100°C at a rate of 1°C / min and maintain for 5-15 minutes.

5. A manufacturing process for high-strength cotton rattan according to claim 1, characterized in that: The finished product in step S4 has a width tolerance of ±0.15 mm, a thickness tolerance of ±0.1 mm, a tensile strength of ≥25 MPa, and a bending fatigue life of ≥5000 times.

6. The manufacturing process of a high-strength cotton rattan according to claim 1, characterized in that: Also includes finishing process: A constant tension winding device with a tension of 0.8-1.5N is used for winding.

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