Ultrahigh-count pure cotton fabric as well as production process and textile thereof

Abstract

The invention belongs to the technical field of textiles, and particularly discloses an ultrahigh-count pure cotton fabric, a production process thereof and a textile. The process comprises the following steps: material selection: selecting cotton as a raw material, wherein the cotton comprises Xinjiang long stapled cotton and Egypt long stapled cotton; opening picking; combing; spinning: taking polylactic acid fibers as carrier fibers, and carrying out carrier spinning by adopting siro compact spinning; weaving: an air-jet weaving method is adopted, and the warping tension is 0.2-0.4 cN; the fabric is desized, boiled off and bleached through a one-step method, and the polylactic acid carrier is removed; and dyeing and finishing: carrying out plasma pretreatment on the fabric before printing and dyeing. High strength, low hairiness and high evenness of yarns are achieved, carrier fibers can be removed through one-step desizing, scouring and bleaching, the dyeing uniformity and glossiness of the fabric are improved through plasma pretreatment before printing and dyeing, fiber damage and production energy consumption can be reduced, the problems of unstable production quality, low efficiency and the like of the high-count fabric are solved, and the production cost is reduced. The product performance and the industrial application value are improved.

Description

Technical Field

[0001] The present invention relates to the field of textile technology, in particular to an ultra-high count pure cotton fabric and a production process thereof, and textiles. Background Art

[0002] Ultra-high count fabrics refer to fabrics with extremely high yarn counts and extremely fine fibers, typically woven from high-count yarns with a count of 120s or above. With the advancement of textile technology, ultra-high count fabrics have gradually become the main material of choice for high-end clothing, home textiles, and professional use, due to their extreme comfort, delicate feel, gloss, and excellent moisture absorption. The textile technology and post-processing of these fabrics are more technically difficult and complex than traditional fabrics, and require extremely high yarn quality, involving multiple process links such as spinning, weaving, printing and dyeing, and finishing. The main problems currently faced in the production of such fabrics are: 1. Yarn quality is difficult to control: It is difficult to meet the requirements for hairiness, evenness and strength of high-count yarns at the same time.

[0003] 2. Fibers are easily damaged: During the cotton cleaning, opening and carding processes, fine fibers are easily damaged, resulting in a high short fiber rate, which affects the yarn quality.

[0004] 3. Low weaving efficiency: The traditional weaving process has insufficient control over the tension of high-count and high-density yarns, resulting in a high breakage rate and low weaving efficiency.

[0005] 4. Poor dyeing and finishing effects: Insufficient dye penetration leads to poor color uniformity; traditional finishing technology is difficult to give the fabric excellent gloss and functionality. Summary of the Invention

[0006] In view of the shortcomings of the prior art described above, the purpose of the present invention is to provide an ultra-high count pure cotton fabric and its production process and textiles, and to achieve efficient and high-quality production of high-count fabrics by optimizing each process link.

[0007] To achieve the above-mentioned and other related purposes, the present invention provides a production process for ultra-high count pure cotton fabrics, comprising the following steps: S1. Material selection: The raw material is cotton, including Xinjiang long-staple cotton and Egyptian long-staple cotton; S2, opening and cleaning cotton; S3, combing; S4, spinning: using polylactic acid fiber as carrier fiber, and adopting siro compact spinning for carrier spinning; S5, Weaving: Air-jet weaving method is adopted, and the warping tension is 0.2 cN~0.4 cN; S6. Pretreatment: Desizing, scouring and bleaching the fabric in one step, and removing the polylactic acid carrier; S7. Dyeing and finishing: Before printing and dyeing, the fabric is subjected to plasma pretreatment.

[0008] Furthermore, the cotton includes Xinjiang long-staple cotton and Egyptian long-staple cotton in a weight ratio of 65-80:20-35.

[0009] Furthermore, the fiber length of the Egyptian long-staple cotton is 35 mm to 38 mm.

[0010] Furthermore, the production process also includes a preliminary impurity removal process, which is carried out before the cotton opening and cleaning process. The preliminary impurity removal process uses a multi-layer screen to remove cotton impurities, and the multi-layer screen used includes at least two layers of screens with apertures of 3.5 mm to 5 mm and 2 mm to 3 mm respectively.

[0011] Furthermore, the process parameter conditions of the cotton opening and cleaning process include: a beating roller speed of 700 rpm to 1100 rpm, a roller gap of 9 mm to 12 mm, an air flow velocity of 8 m / s to 12 m / s, a cotton layer thickness of 10 mm to 16 mm, and a relative humidity of 60% to 68%.

[0012] Furthermore, the cotton opening and cleaning process is processed using a multi-layer screen, and the multi-layer screen used includes at least four layers of screens with apertures of 2 mm to 3 mm, 1.2 mm to 2 mm, 0.6 mm to 1 mm, and 0.3 mm to 0.6 mm, respectively.

[0013] Furthermore, the process parameters of the combing process include: cotton feeding speed of 60 kg / h~80 kg / h, card clothing density of 650~750 needles / square inch, front needle tooth angle of 55°~60°, rear needle tooth angle of 50°~55°, cotton web density of 0.12 g / cm 2 ~0.15 g / cm 2 .

[0014] Furthermore, in the combing process, antistatic oil is sprayed on the cotton bundle before feeding.

[0015] Furthermore, a carding machine is used for combing, wherein the carding machine comprises needle teeth, and the needle teeth are coated with a polyimide nano-coating.

[0016] Furthermore, the polylactic acid fiber has a fineness of 1.2 dtex to 3 dtex.

[0017] Furthermore, in the spinning process, the weight ratio of the cotton fiber to the carrier fiber is 75-85:15-25.

[0018] Furthermore, the spinning process parameter conditions include: 4-pass fine drawing, 8 to 10 combined strips, a drafting roller gap of 0.17 mm to 0.24 mm, a drafting ratio of 1.2 to 1.4 times; an air flow pressure of 0.4 Mpa to 0.55 Mpa; a twist of 3000 twists / m to 3600 twists / m; and a strip evenness CV value of ≤1%.

[0019] Furthermore, in the spinning process, the twisting angle of the fiber bundle is controlled to be symmetrical by a guide plate before the merging point.

[0020] Furthermore, during weaving, the sizing material includes starch and polyvinyl alcohol, and the dissolving temperature is 50°C to 60°C.

[0021] Furthermore, during spinning and / or weaving, static electricity is neutralized by a negative ion generator.

[0022] Furthermore, the pretreatment process uses a pretreatment liquid to desize, scour and bleach the fabric in a one-step method and remove the polylactic acid fiber. The pretreatment liquid includes caustic soda and hydrogen peroxide, the pretreatment temperature is 90°C to 115°C, and the pretreatment time is 45 to 90 minutes.

[0023] Furthermore, based on owf, the pretreatment solution includes 3% to 5% NaOH, 3% to 4% H2O2, 0.5% to 1% sodium tripolyphosphate, and 0.5% to 1% penetrant JFC.

[0024] Furthermore, the plasma pretreatment conditions include: temperature 40° C. to 70° C., voltage 2 kV to 4 kV, frequency 40 Hz to 50 Hz, time 3 to 5 minutes, and treatment with oxygen.

[0025] Furthermore, the dyeing and finishing process also includes post-finishing after printing and dyeing to obtain finished fabrics.

[0026] The present invention also provides an ultra-high count pure cotton fabric produced by the above-mentioned process.

[0027] The present invention also provides a textile comprising the ultra-high count pure cotton fabric described above.

[0028] As described above, the ultra-high count pure cotton fabric, its production process, and textiles of the present invention have the following beneficial effects: The present invention mainly uses Xinjiang long-staple cotton and adds Egyptian long-staple cotton. By optimizing the opening and cleaning, carding, spinning, weaving and dyeing and finishing processes, fiber damage is reduced and the quality of cotton fibers and yarns is improved, thereby producing a high-quality ultra-high-count pure cotton fabric. At the same time, the production energy consumption is reduced, and the problems of unstable quality and low efficiency in the existing high-count fabric production are solved, thereby significantly improving the industrial application value.

[0029] Among them, the materials selected are mainly Xinjiang long-staple cotton, and the addition of Egyptian long-staple cotton can enhance the strength of the yarn and the glossiness of the fabric.

[0030] In the blowroom and combing processes, low-intensity carding and multi-level impurity removal techniques, controlled process parameters, and improved processing equipment (such as screens) have reduced the short fiber rate and improved cleanliness, thereby improving the quality of the cotton fiber and, in turn, the yarn. In the spinning process, polylactic acid fiber is used as the carrier fiber, combined with Siro compact spinning technology, to achieve high yarn strength, low hairiness, and high yarn uniformity. In the weaving process, the air-jet weaving method is adopted to ensure uniform yarn tension by controlling the tension; during sizing, the sizing material is a compound of starch and polyvinyl alcohol, and the use of low-temperature sizing can reduce the dissolution of the polylactic acid fiber carrier, while making it more convenient to remove the carrier fiber and sizing in one step during subsequent processing.

[0031] In the pre-treatment process, descaling and bleaching can be performed in one step to remove the pulp and carrier fibers, and the descaling and bleaching one-step method can be used to remove the pulp and carrier fibers, which can reduce processing energy consumption.

[0032] In the dyeing and finishing process, plasma pretreatment before printing and dyeing can improve the hydrophilicity of the fabric and optimize the dye permeability, thereby improving the dyeing uniformity and glossiness of the fabric.

[0033] In the spinning and weaving process, static electricity can be neutralized by using a negative ion generator, which can reduce static electricity, thereby reducing hairiness and end breakage. DETAILED DESCRIPTION

[0034] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention.

[0035] In the present invention, unless otherwise specified, the term "plurality" means two or more.

[0036] The character " / " indicates that the preceding and following objects are in an "or" relationship. For example, A / B means: A or B.

[0037] The term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0038] An embodiment of the present invention provides a production process for ultra-high count pure cotton fabrics, comprising the following steps: S1. Material selection: The raw material is cotton, including Xinjiang long-staple cotton and Egyptian long-staple cotton; S2, opening and cleaning cotton; S3, combing; S4, spinning: using polylactic acid fiber as carrier fiber, and adopting siro compact spinning for carrier spinning; S5, Weaving: Air-jet weaving method is adopted, and the warping tension is 0.2 cN~0.4 cN; S6. Pretreatment: Desizing, scouring and bleaching the fabric in one step, and removing the polylactic acid fiber; S7. Dyeing and finishing: Before printing and dyeing, the fabric is subjected to plasma pretreatment.

[0039] The above-mentioned embodiment of the present invention mainly uses Xinjiang long-staple cotton and adds Egyptian long-staple cotton. By optimizing the spinning, weaving and dyeing and finishing processes, fiber damage is reduced and the quality of cotton fibers and yarns is improved, thereby producing a high-quality ultra-high-count pure cotton fabric. At the same time, it also reduces production energy consumption, solves the problems of unstable quality and low efficiency in the existing high-count fabric production, and significantly improves the value of industrial application. Among them, compared with using Xinjiang long-staple cotton alone, the choice of blending Xinjiang long-staple cotton with Egyptian long-staple cotton can improve the uniformity, strength and glossiness of the yarn while ensuring output; using polylactic acid fiber as the carrier fiber during spinning, combined with siro compact spinning technology, can reduce hairiness and improve the yarn uniformity, strength and smoothness; air-jet weaving is adopted during weaving, such as weaving with an air-jet loom, and tension-free warping equipment can be used. The dynamic tension control system can monitor and control the tension range in real time within 0.2 cN~0.4 cN to ensure uniform yarn tension; during pre-treatment, descaling and bleaching can be carried out in a one-step method to remove sizing and carrier fibers and reduce processing energy consumption; the fabric is pre-treated with plasma before printing and dyeing, which increases the hydrophilicity of the fabric, improves the dye permeability and color uniformity, and at the same time improves the gloss and strength of the fabric.

[0040] In some embodiments, the cotton comprises Xinjiang long-staple cotton and Egyptian long-staple cotton in a weight ratio of 65-80:20-35. Xinjiang long-staple cotton is primarily used, and the addition of Egyptian long-staple cotton enhances yarn strength and fabric gloss. In one specific embodiment, Xinjiang long-staple cotton and Egyptian long-staple cotton are selected as raw materials, with Xinjiang long-staple cotton accounting for 65%-80% by weight and Egyptian long-staple cotton accounting for 20%-35% by weight. Using too much Egyptian long-staple cotton increases costs; using too little Egyptian long-staple cotton reduces the gloss of the finished fabric.

[0041] In some embodiments, the fiber length of the Egyptian cotton is 35 mm to 38 mm. Egyptian cotton in this length range is high-quality Egyptian cotton. Blending high-quality Egyptian cotton with Xinjiang long-staple cotton is more conducive to improving yarn strength and fabric gloss.

[0042] In some embodiments, the production process further includes a preliminary impurity removal process, which is performed before the cotton opening and cleaning process. The preliminary impurity removal process uses a multi-layer screen to remove cotton impurities, and the multi-layer screen used includes at least two layers of screens with apertures of 3.5 mm to 5 mm and 2 mm to 3 mm, respectively. Preliminary impurity removal is mainly used to remove most impurities in the raw cotton, especially large particles such as cotton seeds and seed cotton. Before cotton opening and cleaning, preliminary impurity removal can remove most impurities and larger fiber bundles, allowing the cotton opening and cleaning process to more effectively loosen and mix fibers, reduce the impurity content in the cotton opening and cleaning process, thereby reducing the load on subsequent processes and improving overall production efficiency.

[0043] Because the cotton used is long and fine, and requires high cleanliness, a low-intensity combing and multi-layer impurity removal process is used during the cleaning process. This can reduce the short fiber rate and improve cleanliness, thereby improving the quality of the cotton fibers and, ultimately, the yarn quality. In some embodiments, the process parameters for the cleaning process include: a beating roller speed of 700 to 1100 rpm, a roller gap of 9 mm to 12 mm, an airflow velocity of 8 m / s to 12 m / s, a cotton layer thickness of 10 mm to 16 mm, and a relative humidity of 60% to 68%.

[0044] In some embodiments, the cotton opening and cleaning process is processed using a multi-layer screen, and the multi-layer screen used includes at least four layers of screens with apertures of 2 mm to 3 mm, 1.2 mm to 2 mm, 0.6 mm to 1 mm, and 0.3 mm to 0.6 mm, respectively.

[0045] In some embodiments, the combing process parameters include: cotton feeding speed 60 kg / h~80 kg / h, card clothing density 650~750 needles / square inch, front needle tooth angle 55°~60°, rear needle tooth angle 50°~55°, cotton web density 0.12g / cm 2 ~0.15 g / cm 2 .

[0046] In some embodiments, the combing process involves spraying the cotton tufts with an antistatic oil selected from dimethicone, cocamidopropyl betaine, monooleate, and the like before feeding. The antistatic oil is typically diluted to a 0.3% to 0.5% concentration before spraying. Spraying the cotton tufts with the antistatic oil before feeding improves fiber slippage and further reduces short fiber rate and fiber damage during the combing process.

[0047] In some embodiments, a carding machine is used for combing, wherein the carding machine includes needle teeth coated with a polyimide nano-coating, which can further reduce the short fiber rate and fiber damage during the carding process.

[0048] Polylactic acid (PLA) is a polymer material formed by the polymerization of small-molecule lactic acid produced by microbial fermentation of biomass feedstocks (such as corn, sugar beets, sucrose, and straw cellulose). It is a thermoplastic polymer with excellent solubility, outstanding crystallinity, transparency, and spinnability. PLA fiber, commonly known as "milky silk," is a new type of green fiber produced from PLA by spinning. Commonly used PLA fibers can be divided into three categories: PLA filament, PLA staple fiber, and PLA composite fiber. The cotton used in the present invention has a low fineness, making siro compact spinning suitable for carrier fibers of a relatively small fineness. In some embodiments, the PLA fiber has a fineness of 1.2 dtex to 3 dtex.

[0049] In some embodiments, the spinning process comprises a weight ratio of cotton fiber to carrier fiber of 75-85:15-25. During spinning, the carrier fiber ratio should not be too high. If it is too high, the yarn hairiness will increase, making removal more difficult. Insufficient removal will result in a stiff surface of the finished fabric. Insufficient removal will result in low fabric strength. If it is too low, the yarn strength will be insufficient, reducing weaving efficiency.

[0050] In some embodiments, the spinning process parameters include: four-pass drawing, 8-10 combined strands, a drafting roller gap of 0.17 mm to 0.24 mm, a draft ratio of 1.2 to 1.4, an airflow pressure of 0.4 MPa to 0.55 MPa, a twist of 3000 to 3600 twists / m, and a yarn evenness CV value of ≤1%. Controlling these process parameters can further reduce hairiness and improve fiber alignment, while also enhancing yarn uniformity, strength, and smoothness.

[0051] In some embodiments, in the spinning process, the fiber bundles are controlled to have symmetrical twist angles by guide plates before the merging point. Precision guide plates are installed before the merging point of the siro spinning fiber bundles to ensure symmetrical twist angles, improve fiber arrangement, and improve the uniformity and strength of the yarn. The guide plates are made of high-hardness, wear-resistant materials such as alumina ceramics or chrome-plated alloy steel, and the surface needs to be polished with Ra ≤ 0.2 μm. The guide plate has an overall V-shaped structure with an opening angle of 60°~70° and a guide groove depth of 3 mm~4 mm. The guide plate installation position is 5 mm~9 mm away from the front roller, 20 mm~35 mm away from the fiber convergence point, and the horizontal inclination angle is ≤3%.

[0052] In some embodiments, during weaving, the sizing material includes starch and polyvinyl alcohol (PVA), with a mass ratio of starch to PVA of, for example, 45-55:27-32. The PVA may be, for example, acrylamide-modified PVA or sulfonated PVA. The sizing temperature (i.e., the temperature at which the starch gelatinizes and the PVA dissolves) is 50°C to 60°C. Using a composite starch and PVA sizing material at a low temperature reduces the dissolution of the polylactic acid fiber carrier and facilitates the one-step removal of the carrier fiber and sizing during subsequent processing. Furthermore, in some embodiments, the slurry also includes a biological enzyme decomposer, a penetrant, a wax flake and glycerol, and the mass ratio of starch, polyvinyl alcohol, biological enzyme decomposer, penetrant, wax flake and glycerol in the slurry is, for example, 45~55:27~32:2.2~2.6:0.5~0.6:2.7~3.3:0.7~0.9; the biological enzyme decomposer is, for example, a DDF composite catalyst, etc., and the DDF composite catalyst is a white powdery substance made of polyacrylonitrile as raw material, which is mixed with α-amylase after high temperature and high pressure treatment; the penetrant is, for example, a penetrant JFC, etc.; the solid content of the slurry is 9.5%~10.5%, the pH value of the slurry is, for example, 6.2~7.0, the sizing vehicle speed is, for example, 58 m / min~62 m / min, the sizing pressure is, for example, 22 kN~24 kN, and the sizing rate is, for example, 12%~14%.

[0053] In some embodiments, during spinning and / or weaving, a negative ion generator is used to neutralize static electricity. By installing a negative ion generator, static electricity generated is neutralized, reducing hairiness and end breakage.

[0054] In some embodiments, the pretreatment process uses a pretreatment solution to desize, scour, and bleach the fabric in a one-step process, removing polylactic acid fibers. The pretreatment solution comprises caustic soda and hydrogen peroxide, with a pretreatment temperature of 90°C to 115°C and a pretreatment time of 45 to 90 minutes. Compared to performing desizing, scouring, and bleaching separately, a one-step desizing, scouring, and bleaching process can shorten the production process, reduce energy consumption, and achieve energy conservation and environmental protection. Furthermore, the sizing material used in the present invention, primarily composed of starch and PVA, is suitable for desizing with an alkali (such as caustic soda) and an oxidant (hydrogen peroxide). Using a combination of caustic soda and hydrogen peroxide as the pretreatment solution can also simultaneously remove polylactic acid fibers. Furthermore, in some embodiments, the pretreatment solution comprises, on an owf basis, 3% to 5% NaOH, 3% to 4% H₂O₂, 0.5% to 1% sodium tripolyphosphate, and 0.5% to 1% penetrant JFC. (owf) = On weight of the fabric. This is a unit of concentration that refers to the ratio of the weight of each component in the pretreatment solution to the weight of the fabric. For example, based on the weight of the fabric, the percentage of NaOH mass relative to the fabric.

[0055] In some embodiments, the plasma pretreatment conditions include: a temperature of 40°C to 70°C, a voltage of 2 kV to 4 kV, a frequency of 40 Hz to 50 Hz, a duration of 3 to 5 minutes, and oxygen. Because high-yarn count fabrics have a high density and dyes have difficulty penetrating the fibers, plasma pretreatment of the fabric during the dyeing and finishing process can increase the fabric's hydrophilicity. Subsequent conventional printing, dyeing, and finishing can yield a uniform color and enhance the fabric's gloss and strength.

[0056] In some embodiments, the dyeing and finishing process further includes post-finishing after printing and dyeing to obtain the finished fabric. Post-finishing is a process that uses chemical or physical methods to improve the appearance and feel of the fabric, enhance its wearability, or impart special functions. Post-finishing methods can be divided into two categories: physical / mechanical finishing and chemical finishing. The method of choice is based on the purpose and effect of the finishing. Physical / mechanical finishing includes, but is not limited to, stentering, calendering, electro-lighting, embossing, and mechanical pre-shrinking. Chemical finishing includes, but is not limited to, softening, stiffening, whitening, and shrink-proofing.

[0057] Another embodiment of the present invention provides an ultra-high count pure cotton fabric produced by the process described above.

[0058] Another embodiment of the present invention provides a textile comprising the ultra-high count pure cotton fabric as described above.

[0059] In some embodiments, the textiles are clothing or home textiles. The ultra-high count pure cotton fabric provided by the present invention is very suitable for use as a fabric for high-end clothing, such as shirts and suits, and the ultra-high count pure cotton fabric can be used as a lining for suits. The ultra-high count pure cotton fabric provided by the present invention is also very suitable for use in high-end home textiles, such as bed sheets and quilt covers.

[0060] The following specific examples are given to illustrate the present invention in detail. It should also be understood that the following examples are only used to specifically illustrate the present invention and cannot be understood as limiting the scope of protection of the present invention. Some non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention all fall within the scope of protection of the present invention. The specific process parameters and the like in the following examples are only examples within a suitable range, that is, those skilled in the art can make a selection within a suitable range based on the description herein, and are not limited to the specific numerical values exemplified below.

[0061] Example 1 This embodiment provides an ultra-high count pure cotton fabric, the production process of which is as follows: S1. Material selection: The raw materials are 75% Xinjiang long-staple cotton and 25% Egyptian long-staple cotton. The fiber length of Egyptian long-staple cotton is 35 mm~38 mm.

[0062] S2. Opening and Blowing: Before opening and blowing, preliminary impurity removal is performed using two layers of screens with apertures of 4 mm and 2.5 mm, respectively. Blowing process parameters: 900 rpm beating roller speed, 10 mm roller gap, 10 m / s airflow velocity, 12 mm cotton layer thickness, 65% relative humidity; four layers of screens are used, with apertures of 2.5 mm, 1.5 mm, 0.8 mm, and 0.4 mm, respectively.

[0063] S3, combing: cotton feeding speed 70 kg / h, card clothing density 700 needles / square inch, front needle tooth angle 58°, rear needle tooth angle 52°, cotton web density 0.13g / cm 2 Before feeding, the cotton bundle is sprayed with an antistatic oil, which is dimethyl silicone oil, prepared with water to form a 0.4% dimethyl silicone oil aqueous solution. Combing is performed using a carding machine, which includes needle teeth coated with a polyimide nano-coating.

[0064] S4: Spinning: Polylactic acid (PLA) fiber is used as the carrier fiber, using Siro compact spinning. The carrier fiber fineness is 2.0 dtex, accounting for 20% by weight, and the cotton fiber accounts for 80% by weight. Four fine drawing passes are used, with 10 strands combined, a drafting roller gap of 0.20 mm, and a draft ratio of 1.4. The airflow pressure is 0.5 MPa, the twist is 3200 twists / m, and the yarn evenness (CV) value is controlled at ≤1%. A precision guide plate is installed before the fiber bundle combining point in Siro spinning to ensure symmetrical twist angles. The guide plate is made of alumina ceramic and requires a surface polishing of Ra ≤ 0.2 μm. The guide plate has an overall V-shaped structure with a 60° opening angle and a guide groove depth of 4 mm. The guide plate is installed 5 mm from the front roller and 20 mm from the fiber convergence point, with a horizontal inclination of ≤3%. A negative ion generator is installed to neutralize static electricity.

[0065] S5. Weaving: Weaving is carried out on an air-jet loom. The slurry is prepared with 50 kg starch, 30 kg acrylamide-modified polyvinyl alcohol, 2.4 kg DDF composite catalyst, 0.5 kg penetrant JFC, 3.1 kg wax flakes and 0.8 kg glycerol. The solid content is 10%, the volume is 750 L, the preparation temperature is 60 °C, the slurry pH is 6.8, the sizing speed is 60 m / min, the sizing pressure is 23 kN, and the sizing rate is 13%. The warping tension is controlled at 0.3 cN. A negative ion generator is installed to neutralize static electricity.

[0066] S6. Pretreatment: Desize, scour, and bleach the fabric in a one-step process using a pretreatment solution to remove polylactic acid fibers. The pretreatment solution, calculated as owf, consists of 4% NaOH, 3.5% H₂O₂, 1% sodium tripolyphosphate, and 1% JFC. The pretreatment temperature is 95°C and the treatment time is 60 minutes.

[0067] S7. Dyeing and Finishing: Before dyeing and printing, the fabric undergoes plasma pretreatment. The plasma pretreatment conditions include: temperature 50°C, voltage 3 kV, frequency 50 Hz, duration 3 minutes, and oxygen treatment. The finished fabric is then dyed and finished.

[0068] Example 2 This embodiment provides an ultra-high count pure cotton fabric, the production process of which differs from that of embodiment 1 only in that: S1. Material selection: 80% Xinjiang long-staple cotton, 20% Egyptian long-staple cotton. The fiber length of Egyptian long-staple cotton is 35 mm~38 mm.

[0069] S2. Opening and cleaning: the beating roller speed is 1100 rpm, the air flow speed is 12 m / s; the apertures of the four-layer screens are 2 mm, 1.2 mm, 0.6 mm, and 0.3 mm respectively.

[0070] S3, combing: cotton feeding speed 60kg / h, card clothing density 750 needles / square inch, front needle tooth angle 60°, rear needle tooth angle 55°, cotton web density 0.12g / cm 2 Before feeding, the cotton bundle is sprayed with an antistatic oil, which is dimethyl silicone oil, prepared with water to form a 0.5% dimethyl silicone oil aqueous solution. Combing is performed using a carding machine, which includes needle teeth coated with a polyimide nano-coating.

[0071] S4. Spinning: Polylactic acid (PLA) fiber is used as the carrier fiber, using Siro compact spinning. The carrier fiber fineness is 2.0 dtex, accounting for 25% by weight, and cotton fiber accounts for 75% by weight. Four fine drawing passes are used, with 10 strands combined, a drafting roller gap of 0.18 mm, and a draft ratio of 1.4. The airflow pressure is 0.5 MPa, the twist is 3600 twists / m, and the yarn evenness (CV) value is controlled at ≤1%. A precision guide plate is installed before the fiber bundle combining point in Siro spinning to ensure symmetrical twist angles. The guide plate is made of alumina ceramic and requires a surface polishing of Ra ≤ 0.2 μm. The guide plate has an overall V-shaped structure with a 70° opening angle and a guide groove depth of 3 mm. The guide plate is installed 9 mm from the front roller and 30 mm from the fiber convergence point, with a horizontal inclination of ≤3%. A negative ion generator is installed to neutralize static electricity.

[0072] S5. Weaving: Weaving is carried out on an air-jet loom. The slurry is prepared with 45kg starch, 32kg acrylamide-modified polyvinyl alcohol, 2.2kg DDF composite catalyst, 0.6kg penetrant JFC, 3.3kg wax flakes and 0.9kg glycerol. The solid content is 10.5%, the volume is 780L, the slurry pH is 6.2, the speed is 60m / min, the sizing pressure is 24kN, and the sizing rate is 16%. The warping tension is controlled at 0.4cN. A negative ion generator is installed to neutralize static electricity.

[0073] S6. Pretreatment: Desize, scour, and bleach the fabric in a one-step process using a pretreatment solution to remove the polylactic acid fibers. The pretreatment solution, calculated on an owf basis, consists of 5% NaOH, 4% H₂O₂, 1% sodium tripolyphosphate, and 1% JFC. The pretreatment temperature is 115°C, and the treatment time is 45 minutes.

[0074] S7. Finishing: Before printing and dyeing, the fabric is subjected to plasma pretreatment. The plasma pretreatment conditions include: temperature 60°C, voltage 4 kV, frequency 50 Hz, time 3 minutes, and oxygen treatment. The finished fabric is then obtained through printing, dyeing, and finishing.

[0075] Example 3 This embodiment provides an ultra-high count pure cotton fabric, the production process of which differs from that of embodiment 1 only in that: S1. Material selection: 65% Xinjiang long-staple cotton, 35% Egyptian long-staple cotton. The fiber length of Egyptian long-staple cotton is 35 mm~38 mm.

[0076] S2. Opening and cleaning: the beating roller speed is 700 rpm, the air flow velocity is 9 m / s; the apertures of the four-layer screen are 3 mm, 2 mm, 1 mm, and 0.6 mm respectively.

[0077] S3, combing: cotton feeding speed 80kg / h, card clothing density 650 needles / square inch, front needle tooth angle 55°, rear needle tooth angle 50°, cotton web density 0.15g / cm 2 Before feeding, the cotton bundle is sprayed with an antistatic oil, which is dimethyl silicone oil, prepared with water to form a 0.3% dimethyl silicone oil aqueous solution. Combing is performed using a carding machine, which includes needle teeth coated with a polyimide nano-coating.

[0078] S4. Spinning: Polylactic acid (PLA) fiber is used as the carrier fiber, using Siro compact spinning. The carrier fiber fineness is 2.0 dtex, accounting for 15% by weight, and cotton fiber accounts for 85% by weight. Four fine drawing passes are used, with 10 strands combined, a drafting roller gap of 0.24 mm, and a draft ratio of 1.4. Airflow pressure is 0.5 MPa, twist is 3000 twists / m, and the yarn evenness (CV) value is controlled at ≤1%. A precision guide plate is installed before the fiber bundle combining point in Siro spinning to ensure symmetrical twist angles. The guide plate is made of chrome-plated alloy steel and requires a surface polishing of Ra ≤ 0.2μm. The guide plate has an overall V-shaped structure with a 60° opening angle and a guide groove depth of 3mm. The guide plate is installed 9mm from the front roller and 35mm from the fiber convergence point, with a horizontal inclination of ≤3%. A negative ion generator is installed to neutralize static electricity.

[0079] S5. Weaving: Weaving is carried out on an air-jet loom. The slurry is prepared from 55kg starch, 27kg acrylamide-modified polyvinyl alcohol, 2.6kg DDF composite catalyst, 0.5kg penetrant JFC, 2.7kg wax flakes and 0.7kg glycerol. The solid content is 9.5%, the volume is 730L, the slurry pH is 6.8, the speed is 62m / min, the sizing pressure is 22kN, and the sizing rate is 14%. The warping tension is controlled at 0.4cN. A negative ion generator is installed to neutralize static electricity.

[0080] S6. Pretreatment: Desize, scour, and bleach the fabric in a one-step process using a pretreatment solution to remove polylactic acid fibers. The pretreatment solution, calculated on an owf basis, consists of 3% NaOH, 3% H₂O₂, 1% sodium tripolyphosphate, and 1% JFC. The pretreatment temperature is 90°C, and the treatment time is 80 minutes.

[0081] S7. Finishing: Before printing and dyeing, the fabric is subjected to plasma pretreatment. The plasma pretreatment conditions include: temperature 40°C, voltage 2 kV, frequency 50 Hz, time 5 minutes, and oxygen treatment. The finished fabric is then obtained through printing, dyeing, and finishing.

[0082] Comparative Example 1 This comparative example provides an ultra-high count pure cotton fabric, the production process of which differs from that of Example 1 only in that: S1. Material: 100% Xinjiang long-staple cotton.

[0083] Comparative Example 2 This comparative example provides an ultra-high count pure cotton fabric, the production process of which differs from that of Example 1 only in that: S2, opening and cleaning, cotton: opening and cleaning cotton adopts two layers of screens, and the apertures of the two layers of screens are 2.5mm and 1.5mm respectively.

[0084] Comparative Example 3 This comparative example provides an ultra-high count pure cotton fabric, the production process of which differs from that of Example 1 only in that: S4, Spinning: No carrier fiber is used. Drafting roller gap is 0.25 mm; twist is 3000 twists / m; CV value is controlled to ≤1.5%.

[0085] Comparative Example 4 This comparative example provides an ultra-high count pure cotton fabric, the production process of which differs from that of Example 1 only in that: S5. Weaving: The warping tension is controlled at 0.6 cN.

[0086] Yarn and fabric performance testing methods 1. Yarn strength: Tested according to ISO 2062, using a single yarn strength meter to test the weft strength, the unit is cN / tex.

[0087] 2. Hairiness index: measured by Uster hairiness tester, the unit is hairiness length (mm).

[0088] 3. Strip uniformity (CV value): According to ISO 16549, use Uster strip uniformity meter to test.

[0089] 4. Fabric gloss: Tested with a gloss meter (60° reflection angle) and calculated by reflectivity in %.

[0090] 5. Fabric strength: According to the standard GB / T 3916-2013, use a tensile testing machine to test, the unit is N.

[0091] The test results are shown in Table 1 below: Table 1 Fabric properties

[0092] Combined with the data in Table 1, we can draw the following conclusions: Comparing Example 1 with Comparative Example 1, it can be seen that the material is mainly Xinjiang long-staple cotton, and adding Egyptian long-staple cotton can enhance the yarn strength and fabric gloss.

[0093] Comparing Example 1 with Comparative Example 2, it can be seen that compared with using two layers of screens, using four layers of screens for opening and cleaning cotton can more effectively remove impurities and short fibers, thereby improving yarn quality and fabric gloss.

[0094] Comparing Example 1 with Comparative Example 3, it can be seen that adding carrier fibers during spinning significantly improves single yarn strength and yarn uniformity, reduces the end-breakage rate during weaving, and improves weaving efficiency.

[0095] Compared with Example 1, the warping tension in Comparative Example 4 was higher, resulting in a high yarn breakage rate and low weaving efficiency. Therefore, controlling the warping tension within the range of 0.2 cN to 0.4 cN ensured uniform yarn tension, reduced the yarn breakage rate during weaving, and improved weaving efficiency.

[0096] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A production process for ultra-high count pure cotton fabric, characterized in that: The process includes the following steps: S1. Material selection: The raw material is cotton, including Xinjiang long-staple cotton and Egyptian long-staple cotton; S2, opening and cleaning cotton; S3, combing; S4, spinning: using polylactic acid fiber as carrier fiber, and adopting siro compact spinning to carry out carrier spinning; S5, Weaving: Air-jet weaving method is adopted, and the warping tension is 0.2 cN~0.4 cN; S6. Pretreatment: Desizing, scouring and bleaching the fabric in one step, and removing the polylactic acid carrier; S7. Dyeing and finishing: Before printing and dyeing, the fabric is subjected to plasma pretreatment.

2. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: The cotton includes Xinjiang long-staple cotton and Egyptian long-staple cotton in a weight ratio of 65-80:20-35; And / or, the fiber length of the Egyptian long-staple cotton is 35 mm to 38 mm.

3. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: The polylactic acid fiber has a fineness of 1.2 dtex to 3 dtex; and / or, in the spinning process, the weight ratio of the cotton fiber to the carrier fiber is 75-85:15-25; And / or, the spinning process parameters include: 4-pass drawing, 8 to 10 combined strands, drafting roller gap of 0.17 mm to 0.24 mm, drafting ratio of 1.2 to 1.4 times; air flow pressure of 0.4 MPa to 0.55 MPa; twist of 3000 twists / m to 3600 twists / m; and CV value of yarn evenness ≤ 1%; And / or, in the spinning process, the twisting angle of the fiber bundle is controlled to be symmetrical by a guide plate before the merging point.

4. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: During weaving, the sizing material includes starch and polyvinyl alcohol, and the dissolving temperature is 50℃~60℃; and / or, neutralizing static electricity by using a negative ion generator during spinning and / or weaving.

5. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: The pretreatment process uses a pretreatment liquid to desize, scour and bleach the fabric in a one-step method and remove polylactic acid fibers. The pretreatment liquid includes caustic soda and hydrogen peroxide. The pretreatment temperature is 90° C. to 115° C. and the pretreatment time is 45 to 90 minutes.

6. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: The plasma pretreatment conditions include: temperature of 40° C. to 70° C., voltage of 2 kV to 4 kV, frequency of 40 Hz to 50 Hz, time of 3 to 5 minutes, and treatment with oxygen.

7. The production process of the ultra-high count pure cotton fabric according to any one of claims 1 to 6, characterized in that: The production process also includes a preliminary impurity removal process, which is performed before the cotton opening and cleaning process. The preliminary impurity removal process uses a multi-layer screen to remove cotton impurities, and the multi-layer screen used includes at least two layers of screens with apertures of 3.5 mm to 5 mm and 2 mm to 3 mm respectively; And / or, the process parameters of the cotton opening and cleaning process include: a beating roller speed of 700 rpm to 1100 rpm, a roller gap of 9 mm to 12 mm, an air flow speed of 8 m / s to 12 m / s, a cotton layer thickness of 10 mm to 16 mm, and a relative humidity of 60% to 68%; And / or, the cotton opening and cleaning process is processed using a multi-layer screen, and the multi-layer screen used includes at least four layers of screens with apertures of 2 mm to 3 mm, 1.2 mm to 2 mm, 0.6 mm to 1 mm, and 0.3 mm to 0.6 mm respectively; And / or, the process parameters of the combing process include: cotton feeding speed of 60 kg / h~80 kg / h, card clothing density of 650~750 needles / square inch, front needle tooth angle of 55°~60°, rear needle tooth angle of 50°~55°, cotton web density of 0.12 g / cm 2 ~0.15 g / cm 2 ; And / or, in the combing process, an antistatic oil is sprayed on the cotton bundle before feeding; And / or, combing is performed using a carding machine, wherein the carding machine comprises needle teeth coated with a polyimide nano-coating.

8. The production process of ultra-high count pure cotton fabric according to claim 1, characterized in that: The dyeing and finishing process also includes post-finishing after printing and dyeing to obtain finished fabrics.

9. An ultra-high count pure cotton fabric produced according to the process according to any one of claims 1 to 8.

10. A textile, characterized in that: The invention comprises the ultra-high count pure cotton fabric according to claim 9.

Images