All-cotton gauze and manufacturing method thereof

Abstract

A manufacturing method of all-cotton gauze comprises the steps that fabric design is conducted, specifically, a double-layer or multi-layer gauze structure is selected, hanging point structures are arranged between the layer structures of gauze, and the gauze is woven through pure cotton yarn; air vortex spinning is adopted, the feeding ratio ranges from 0.94 to 0.97, the spinning speed ranges from 350 m / min to 400 m / min, and the fibers which are opened to be in a single state are coagulated and twisted into plied yarn; the difference between the warp yarn density and the weft yarn density does not exceed 5%, and the hanging point structures between the gauze layer structures are rhombus-shaped; carrying out after-treatment: carrying out physical softening treatment on the gauze through air flapping; and finished product detection: inspecting the appearance quality and internal quality indexes of the gauze. Through the technologies of density balance, rhombus hanging points, vortex plied yarn, air flapping and the like, the slip value is greatly reduced, the hand feeling and the washability are synchronously improved, and meanwhile the essential characteristics of breathability, lightness and thinness of the gauze are maintained.

Description

Technical Field

[0001] The invention relates to the technical field of textile dyeing and finishing, and in particular to a pure cotton gauze and a manufacturing method thereof. Background Art

[0002] Cotton gauze fabric is a sparsely woven cotton fabric with a distinct grid pattern and a fiber composition of 100% cotton. Its distinct warp and weft structure allows for single, double, and multi-layer fabrics. It offers excellent breathability and high thermal conductivity. Its inherent lightness, softness, skin-friendliness, and water absorption make it a popular choice for baby clothes, adult homewear, and pajamas. However, due to its loose structure, gauze is prone to slippage. This is when tension is applied to seams, causing the yarns to slide relative to each other, or even fall off, compromising wearability.

[0003] Currently, the conventional methods to improve slippage in the industry are: one is to increase the density of warp or weft yarns to make the fabric yarns more stable in structure and reduce slippage; the other method is to add anti-slip agents during fabric finishing or reduce the amount of softener to increase the hardness of the fabric to reduce slippage.

[0004] The above-mentioned method of improving slippage will change the structure of the fabric by increasing the density of the warp and weft yarns. Excessive yarn density will directly cause the fabric to no longer be called gauze; and reducing the amount of softener has a great impact on the feel of the fabric, causing the fabric to feel hard and astringent, thus affecting wearing comfort. Summary of the Invention

[0005] The invention discloses a pure cotton gauze and a manufacturing method thereof, and mainly solves the technical problem of improving the slippage phenomenon caused by the loose structure of the gauze while ensuring the fabric structure and fabric feel of the gauze.

[0006] According to the first aspect, an embodiment provides a method for manufacturing pure cotton gauze, comprising:

[0007] Fabric design: Choose a double-layer or multi-layer gauze structure, and set a hanging point structure between the layers of gauze. The gauze is woven with pure cotton yarn;

[0008] Spinning: Vortex spinning is used with a feed ratio of 0.94 to 0.97 and a spinning speed of 350 to 400 m / min, so that the fibers opened into a single state are condensed and twisted into yarn;

[0009] Weaving: The difference between the warp and weft yarn densities does not exceed 5%, and the hanging point structure between the gauze layers is diamond-shaped;

[0010] Finishing: Physical softening treatment of gauze by air beating;

[0011] Finished product inspection: inspect the appearance quality and internal quality indicators of the gauze.

[0012] In another embodiment, the warp yarn density and the weft yarn density of the gauze are the same.

[0013] In another embodiment, the warp yarn density and the weft yarn density of the gauze tend to be the same.

[0014] In another embodiment, the diamond-shaped hanging point structures between the gauze layer structures adopt a 1 cm×1 cm spacing.

[0015] In another embodiment, the ply yarn is spun by plying and twisting a plurality of single yarns, the count after plying is consistent with that of the single yarn, and the ply yarn has an uneven outer surface.

[0016] In another embodiment, the vortex-spun yarn includes a central straight core yarn and a covering yarn wrapped around the outer layer of the straight yarn.

[0017] In another embodiment, the spinning process adopts an air-jet vortex spinning machine with the following parameters: TDR drafting multiple 230 times, roller spacing 40mm×43mm.

[0018] In another embodiment, during the spinning process, the warp yarn and the weft yarn are twisted in opposite directions, the warp yarn is twisted in the positive direction, and the weft yarn is twisted in the reverse direction.

[0019] In another embodiment, the woven fabric is dyed with reactive dyes on a continuous pad dyeing machine before being finished.

[0020] According to the second aspect, an embodiment provides a pure cotton gauze, which is manufactured using the above-mentioned manufacturing method.

[0021] According to the pure cotton gauze and its manufacturing method in the above-mentioned embodiment, vortex spinning is adopted as the spinning method, and the woven fiber is coated yarn with obvious fiber orientation. The feed ratio is selected between 0.94 and 0.97, and the wrapped fibers are more, and the relative slip is reduced by increasing the yarn friction coefficient; the difference in warp and weft density of the gauze during weaving is ≤5%, compared with the traditional gauze in which the warp density is greater than the weft density, the slip is improved by reducing the warp density and increasing the weft density without changing the total density; the diamond hanging point structure can better stabilize the gauze structure and improve the slip compared with the square hanging point structure; the physical softening by air beating is reduced without adding softener, which reduces the slip caused by adding softener and is more washable. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 Schematic diagram of the process for manufacturing pure cotton gauze. DETAILED DESCRIPTION

[0023] The present invention will be further described in detail below by means of specific embodiments in conjunction with the accompanying drawings. Similar elements in different embodiments are numbered with associated similar elements. In the following embodiments, many detailed descriptions are provided to enable the present application to be better understood. However, those skilled in the art will readily appreciate that some of the features may be omitted in different circumstances, or may be replaced by other elements, materials, or methods. In some cases, some operations related to the present application are not shown or described in the specification. This is to avoid the core portion of the present application being overwhelmed by excessive descriptions, and for those skilled in the art, it is not necessary to describe these related operations in detail. They will fully understand the related operations based on the description in the specification and the general technical knowledge in the art.

[0024] In addition, the features, operations, or characteristics described in the specification may be combined in any appropriate manner to form various embodiments. Furthermore, the steps or actions in the method description may be reordered or adjusted in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided solely for the purpose of clearly describing a particular embodiment and are not intended to be mandatory, unless otherwise specified.

[0025] The serial numbers assigned to components herein, such as "first," "second," etc., are used solely to distinguish the objects being described and do not convey any sequential or technical meaning. References to "connection" and "coupling" herein, unless otherwise specified, include both direct and indirect connections (couplings).

[0026] The current gauze structure is loose and prone to slippage. That is, when the seams of the garment are stretched by external forces, the yarns will experience significant relative sliding or even slipping, thus affecting wearability. Conventional methods for improving slippage in the industry include increasing the density of the warp or weft yarns, which structurally makes the fabric yarns more stable and reduces slippage. However, if the yarn density is too high, the fabric cannot be called gauze. Another method is to add anti-slip agents during fabric finishing or reduce the amount of softener used to increase the hardness of the fabric to reduce slippage. Although this method can effectively improve slippage, it has a significant impact on the feel of the fabric, making it feel hard and astringent, affecting wearing comfort.

[0027] The present application discloses a pure cotton gauze and a manufacturing method thereof, which can improve the slippage phenomenon of the gauze caused by the loose structure while maintaining the gauze fabric structure and fabric feel.

[0028] The technical solution of the present application is described in detail below with reference to the embodiments, taking 40S double-layer gauze as an example.

[0029] According to the first aspect, an embodiment provides a method for manufacturing pure cotton gauze, please refer to Figure 1 , including the following steps:

[0030] S1: Fabric design (improving density imbalance);

[0031] The woven fabric in this embodiment is made of double-layer or multi-layer gauze, and hanging point structures are arranged between the layers of the gauze. The gauze is woven with pure cotton yarn.

[0032] In this embodiment, double-layer gauze is selected for weaving, and the yarn count of the original 40S double-layer gauze is changed from 40S to 80S / 2. The difference between the warp yarn density and the weft yarn density is designed to be no more than 5%. It is best to design the warp yarn density and the weft yarn density to be consistent or tend to be consistent, such as 80S / 2×80S / 2, 100×100 (the warp yarn or weft yarn density is 100 per inch).

[0033] Generally, the warp density of woven fabrics is greater than the weft density. The low weft density is mainly used to increase weaving speed, but it will cause the weft slip to deteriorate, that is, the warp yarns slide on the weft yarns. In this embodiment, the warp yarn density and weft yarn density of the gauze are consistent, solving the problem of density imbalance. In this way, the slip is improved without changing the overall density.

[0034] When the warp density and weft density are consistent, the weaving speed is relatively slow. When there are requirements for weaving speed, the warp density and weft density can be adjusted according to specific needs and try to make them consistent. As long as the difference between the warp density and weft density is controlled within 5%, the density imbalance can be improved as much as possible. In this way, without changing the total density, the warp density is reduced and the weft density is increased, thereby improving slippage.

[0035] In this embodiment, a hanging point structure is set between the two layers of gauze. Specifically, a diamond-shaped hanging point structure is used between the gauze layers, with a spacing of 1 cm x 1 cm. The warp and weft yarns are interlaced orthogonally at the hanging points. Compared with the ordinary square hanging point structure, the diamond-shaped hanging point structure can better stabilize the gauze structure and reduce slippage.

[0036] The commonly used square structure has weak interlayer bonding force, while the geometric symmetry of the diamond structure enables it to disperse the load through multi-directional force transmission paths when subjected to stress, reducing local stress concentration, and showing higher fatigue resistance, especially under dynamic loads. It disperses stress through oblique tension, and the stress is more evenly dispersed. It also has strong deformation resistance. The stability of the diamond grid is higher than that of the linear arrangement structure, and can effectively resist lateral torsional deformation, thereby further improving slippage.

[0037] S2: Spinning (increasing yarn friction coefficient);

[0038] The spinning process of this embodiment adopts vortex spinning to make the fibers opened into a single state condense and twist into ply yarn.

[0039] In this embodiment, an air jet vortex spinning machine is used for spinning, for example, an MVS870 air jet vortex spinning machine is used, and the parameter settings are as follows:

[0040] Feed ratio: 0.96, preferably in the range of 0.94-0.97, the proportion of wrapping fiber is increased to 35%. If the feed ratio is greater than 0.97, the friction coefficient will decrease due to insufficient wrapping fiber. When the feed ratio is less than 0.94, the yarn is prone to breakage.

[0041] Spinning speed: 380m / min (350m / min~400m / min);

[0042] TDR draft ratio: 230 times;

[0043] Roller gauge: 40mm×43mm.

[0044] 80S / 2 yarn was obtained.

[0045] In one embodiment, before spinning, the feed ratio is set at 0.96±0.01. The can speed is dynamically adjusted by a servo motor to ensure a stable core yarn tension of 12-13 cN, with the wrapped fiber accounting for 35%. The distance between the front roller and the nozzle is fixed at 20 mm to optimize the wrapping effect. The TDR draft ratio is 230 times, with a 40 mm × 43 mm roller gauge in the main drafting zone, a 2.8 times draft in the middle zone, and a 3.0 times draft in the rear zone. Fiber straightness and drafting force are simultaneously controlled to balance.

[0046] The spinning process is:

[0047] Fiber transport: The sliver is fed into the FA317A draw frame after being drawn three times. The fiber is stretched to 230 times its original length when passing through the main drafting zone. The VOS system monitors drafting fluctuations in real time.

[0048] Eddy current twisting: The spindle assembly runs at a speed of 380m / min, the MSC detection system scans the yarn structure every 5 seconds, and the double-hole nozzle generates a spiral airflow to make the outer fiber evenly wrap around the core wire.

[0049] Yarn winding: The automatic winder takes up the yarn at a take-up ratio of 1.01, and the yarn density is controlled at 0.25g / cm by the air pressure regulating valve. 3 ±3%.

[0050] At the same time, during the spinning process, the workshop is maintained at 25℃±1℃ and RH60%±5% to prevent static electricity from interfering with fiber wrapping. The nozzle is cleaned of lint every 8 hours, and the fiber channel is combed using BH-450-A card clothing.

[0051] In other embodiments, the spinning process and equipment actions can be adjusted according to equipment conditions and on-site needs.

[0052] In this embodiment, the vortex spinning yarn has a straight core yarn in the middle and a covered yarn with wrapped fibers on the outer layer. The fibers are clearly oriented, and the feed ratio is selected in the range of 0.94 to 0.97. There are more wrapped fibers, and the yarn friction coefficient is large, making it less likely to cause relative slippage.

[0053] In this embodiment, the yarn is changed from single yarn to ply yarn, which is spun by twisting multiple single yarns together. The yarn count after plying is consistent with that of the single yarn. While maintaining the consistency of yarn thickness, the outer surface of the ply yarn is uneven compared to the single yarn, which increases friction and thus improves slippage.

[0054] During the spinning process, the warp yarn and the weft yarn are twisted in different directions, the warp yarn is twisted in the positive direction (Z twist), and the weft yarn is twisted in the reverse direction (S twist). Because the twist directions of the warp and weft yarns are inconsistent, the warp and weft yarns can fit closer at the interweaving point and the contact area is larger, thereby increasing the friction and improving slippage.

[0055] S3: weaving (stable diamond hanging point structure);

[0056] In this embodiment, the warp yarn density and the weft yarn density are consistent during weaving, and the hanging point structure between the double layers of gauze is diamond-shaped with a spacing of 1 cm × 1 cm;

[0057] In this embodiment, a Toyota 710 air-jet loom is used for weaving, and the tension is controlled at 2200N (2000-2500N); weaving parameters:

[0058] Warp beam pressure: 300kPa;

[0059] Opening time: 290°;

[0060] Weft insertion time: 85°.

[0061] The diamond hanging point is controlled by a multi-arm harness lifting device, and the harness drawing path is switched every 1 cm.

[0062] In one embodiment, the diamond-shaped hanging point structure needs to be manufactured through the process of pattern plate design - warp yarn drawing - reed configuration - weft insertion - node reinforcement - shaping detection.

[0063] Furthermore, in one embodiment, the diamond hanging points need to be equipped with an electronic dobby machine (such as Stäubli 2870), which cannot be achieved by an ordinary cam opening mechanism.

[0064] In one embodiment, the weaving process is:

[0065] Layered drawing-in: The surface warp yarns are drawn into heald frames 1, 3, 5, and 7, and the bottom warp yarns are drawn into heald frames 2, 4, 6, and 8, and are arranged in a staggered manner according to the "1 empty and 1 drawn-in" rule to ensure that 4 diamond-shaped interweaving anchor points are formed per centimeter.

[0066] Interleaved timing control:

[0067] Shedding stage (0°-120°): Heald frame No. 3 is lifted by 12 mm, and heald frame No. 5 is lifted by 8 mm, forming an upper diamond-shaped shedding;

[0068] Weft insertion stage (90°-240°): The main nozzle and 12 sets of auxiliary nozzles spray in relays, and the weft yarn is precisely embedded in the diamond-shaped cross-linking points;

[0069] Beating-up stage (300°): The reed pushes the weft yarn to the loom, and the take-up motor is started synchronously to take up the cloth;

[0070] Loose warp compensation (320°-360°): The EPC device detects changes in warp beam diameter and automatically compensates for warp let-off;

[0071] Node reinforcement (245°-255°): The LH control box triggers the fixed-point glue spraying device to perform epoxy resin micro-spraying on the diamond nodes.

[0072] During the weaving process, a CCD vision system can be installed to scan and compare the diamond-shaped node distribution every 5 meters, allowing for a ±3% positional deviation. A sensor can be installed on the backrest to monitor the biaxial tension difference, automatically shutting down and issuing an alarm if it exceeds 15%. A weft feeler can also be installed to detect a weft break, causing the loom to reverse 10° within 20ms to repair it.

[0073] In other embodiments, the weaving process and equipment actions can be adjusted according to equipment conditions and on-site needs.

[0074] S4: dyeing (to protect the yarn structure);

[0075] After weaving, the fabric is dyed with reactive dyes on a continuous pad dyeing machine and then finished.

[0076] In one embodiment, gauze generally needs to be pre-treated before dyeing, such as desizing and singeing the grey cloth to remove the sizing and longer hairiness on the surface. Subsequently, hydrogen peroxide bleaching and mercerizing and setting can be added to control weft shrinkage.

[0077] The reactive dyes required for dyeing can be selected according to needs. For example, for dark colors, double-reactive base dyes (such as CI Reactive Black) can be used to improve wet rubbing fastness; for light colors, high light fastness dyes (such as CI Reactive Yellow) can be used in combination with light fastness enhancers.

[0078] Gauze can generally be further fixed in color by subsequent steps such as pre-drying, steaming and soaping after being pad-dyed in a pad dyeing machine.

[0079] S5: Finishing (replacing chemical softeners);

[0080] The dyed and fixed gauze is physically softened by beating it with air.

[0081] In this embodiment, the physical softening treatment by air beating replaces the softening by the softener.

[0082] Specifically, in one embodiment, the gauze needs to be pretreated first, for example: the gauze is spread flat on a conveyor belt, the spinning oil and impurities are removed through a water washing process, the water temperature is controlled, and the initial fluffy state of the fiber is ensured; a double-roller drafting device is used for pre-stretching to eliminate stress in the yarn and control the tension; corresponding air beating equipment (such as MB373 air beating machine) is used, and multiple groups of high-pressure nozzles are arranged in the air beating cabin to perform a cycle operation at a certain period; the air pressure is adjusted to a certain pressure, for example, a high-pressure airflow of 0.25Mpa and a frequency of 3000 times / minute is used to impact the fiber bundle, and the fibers are evenly dispersed and the bonding points are reconstructed through the turbulent effect, thereby improving the fiber discreteness.

[0083] At the same time, dynamic balance adjustment is carried out during the air beating process, the friction coefficient of the gauze surface is monitored in real time, the airflow angle and beating intensity are adjusted through a closed-loop control system, and the air humidity is monitored and maintained to prevent static electricity from interfering with fiber reorganization.

[0084] In other embodiments, the weaving process and equipment actions can be adjusted according to equipment conditions and on-site needs.

[0085] Furthermore, the gauze needs to be pre-shrinked after softening treatment to complete the post-processing of the gauze.

[0086] The gauze fabric manufactured by the manufacturing method of this embodiment does not add softener when it is shaped, but is air-beaten to achieve a fluffy and soft feel, avoiding the slippage caused by adding softener; and compared with the slippery feel of softener, the feel achieved by air-beating is softer and boneless, and is more washable, and will not feel stiff due to the softener being washed away by water.

[0087] S6: Finished product inspection: Inspect the appearance and internal quality of the finished gauze.

[0088] Specifically, according to the second aspect, an embodiment provides a pure cotton gauze, which is manufactured using the above-mentioned manufacturing method.

[0089] In addition to conventional testing, the cotton gauze in this embodiment is also tested for slippage, hand feel, and washability when testing finished products. The slippage value is tested using GB / T21294-2014 (seam slip method); the hand feel is scored using a blind evaluation by professionals (1 point for hard and astringent, 5 points for extremely soft). In other embodiments, other testing methods may also be used for testing.

[0090] In this application, please refer to Table 1 for comparative data of the cotton gauze obtained by the above-mentioned manufacturing method and the existing solution.

[0091]

[0092] Table 1 is a comparison table of the test data of the pure cotton gauze obtained by the above-mentioned manufacturing method and the existing scheme.

[0093] The technical solution of this application is centered on physical structure optimization. Through technologies such as density balance, diamond hanging points, vortex yarn, and air beating, it achieves a significant reduction in slip value and a simultaneous improvement in hand feel and washability, while maintaining the inherent breathability and lightness of the gauze.

[0094] The above examples are used to illustrate the present invention, which are only used to help understand the present invention and are not intended to limit the present invention. Those skilled in the art can make several simple deductions, modifications or substitutions based on the concept of the present invention.

Claims

1. A method for manufacturing pure cotton gauze, characterized in that: include: Fabric design: Choose a double-layer or multi-layer gauze structure, and set a hanging point structure between the layers of gauze. The gauze is woven with pure cotton yarn; Spinning: Vortex spinning is used with a feed ratio of 0.94 to 0.97 and a spinning speed of 350 to 400 m / min, so that the fibers opened into a single state are condensed and twisted into yarn; Weaving: The difference between the warp and weft yarn densities does not exceed 5%, and the hanging point structure between the gauze layers is diamond-shaped; Finishing: Physical softening treatment of gauze by air beating; Finished product inspection: inspect the appearance quality and internal quality indicators of the gauze.

2. The method for producing pure cotton gauze according to claim 1, wherein: The warp density and weft density of the gauze are consistent.

3. The method for producing pure cotton gauze according to claim 1, wherein: The warp density and weft density of the gauze tend to be consistent.

4. The method for producing pure cotton gauze according to claim 1, wherein: The diamond-shaped hanging point structure between the gauze layer structures adopts a spacing of 1 cm×1 cm.

5. The method for producing pure cotton gauze according to claim 1, wherein: The ply yarn is spun by plying and twisting a plurality of single yarns, and the count of the ply yarn after plying is consistent with that of the single yarn, and the ply yarn has an uneven outer surface.

6. The method for producing pure cotton gauze according to claim 1, wherein: The vortex-spun yarn includes a straight core yarn in the middle and a covering yarn wrapped around the outer layer of the straight yarn.

7. The method for producing pure cotton gauze according to claim 1, wherein: The spinning process adopts an air jet vortex spinning machine, and its parameters are: TDR drafting multiple is 230 times, and roller spacing is 40mm×43mm.

8. The method for producing pure cotton gauze according to claim 1, wherein: After weaving, the fabric is dyed with reactive dyes on a continuous pad dyeing machine and then finished.

9. The method for producing pure cotton gauze according to any one of claims 1 to 8, characterized in that: In the spinning process, the warp yarn and the weft yarn are twisted in different directions, the warp yarn is twisted in the positive direction, and the weft yarn is twisted in the negative direction.

10. A pure cotton gauze, characterized in that: The pure cotton gauze is made by the manufacturing method according to any one of claims 1 to 9.

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