Production process of three-proofing sofa fabric

Abstract

The invention discloses a production process of a three-proofing sofa fabric. The production process comprises the following steps: preparation of a suede fabric layer, preparation of a four-axial warp-knitted fabric layer, preparation of a foaming fabric layer and fabric compounding. The step of preparing the suede fabric layer comprises the steps of weaving a suede gray fabric, performing pretreatment, performing plasma treatment, raising, padding a waterborne polyurethane solution, performing primary pre-drying, padding a nano cross-linking agent solution, performing secondary pre-drying and spraying a three-proofing finishing agent; the suede gray fabric comprises a surface comb, a middle comb and a bottom comb, and yarns used by the surface comb are superfine polyester multifilaments; the pretreatment means that the chamois suede grey cloth is soaked in a caustic soda solution, taken out, neutralized with acid, washed with clear water and dried. The four-axial warp-knitted fabric layer adopts four axial yarns, so that the sofa fabric has good tensile property in multiple directions. The three-proofing finishing agent is coated on the surface of the polyurethane coating, so that the three-proofing effect can be effectively improved.

Description

Technical Field

[0001] This invention relates to a production process for a three-proof sofa fabric, belonging to the field of sofa fabric production technology. Background Technology

[0002] With the continuous development of society and the economy, and the continuous improvement of people's living standards, people have increasingly higher requirements for their living standards, especially for home textiles such as sofas, curtains, and bedding. Sofa fabric is a general term for the covering materials used in the sofa manufacturing process. According to raw materials, it can be made of cotton, synthetic fibers, genuine leather, etc. Existing sofa fabrics are usually warp-knitted fabrics, which have shortcomings in dimensional stability. Furthermore, when people sit on the sofa to watch TV, they often drink beverages or eat, inevitably spilling water or oil stains onto the sofa fabric. Therefore, how to prepare a waterproof, oil-proof, and stain-resistant sofa fabric with good dimensional stability has become a problem to be solved. Summary of the Invention

[0003] The purpose of this invention is to provide a manufacturing process for a three-proof sofa fabric that has waterproof and oil-resistant properties and dimensional stability.

[0004] To solve the above-mentioned technical problems, the objective of this invention is achieved as follows: The present invention relates to a production process for a three-proof sofa fabric, comprising the following steps: preparation of a suede fabric layer, preparation of a four-axis warp-knitted fabric layer, preparation of a foamed fabric layer, and fabric lamination; The preparation of the suede fabric layer includes weaving, pretreatment, plasma treatment, napping, impregnation with water-based polyurethane solution, first pre-drying, impregnation with nano crosslinking agent solution, second pre-drying, and spraying with three-proof finishing agent; The suede fabric includes a face comb, a middle comb, and a bottom comb. The yarn used in the face comb is ultra-fine polyester multifilament. The pretreatment refers to immersing the suede fabric in a caustic soda solution, removing it, neutralizing it with acid, and then washing and drying it with clean water. The term "pick-up waterborne polyurethane solution" refers to immersing and padding the napped suede fabric in a waterborne polyurethane solution, with a pick-up rate of 40-50%. The aqueous polyurethane solution comprises 20-30% aqueous polyurethane, 10-15% C16 alkyl polysiloxane, 5-8% nano zinc oxide particles, 3-5% bio-based hydrophobic thickener, and the balance being water. The first pre-drying is performed at 110-120℃ for 1-3 minutes; The padding nano-crosslinking agent solution refers to immersing and padding the pre-dried suede fabric in the nano-crosslinking agent solution once, with a padding rate of 35-40%; the nano-crosslinking agent solution includes 10-20% epoxy siloxane, 3-5% nano zinc oxide particles, 3-5% nano titanium dioxide particles, 10-20% glycerol and 1-2% trisodium citrate; The second pre-drying refers to drying at 95-100℃ for 1-3 minutes; The sprayed three-proof finishing agent refers to spraying a three-proof finishing agent solution onto one side of the nap of the suede fabric after the second pre-drying and then drying it; the three-proof finishing agent solution includes 10-15% three-proof finishing agent, 3-5% easy-to-clean finishing agent DH-302 and 3-5% crosslinking agent; The fabric composite refers to the combination of a suede fabric layer, a four-axis warp-knitted fabric layer, and a foamed fabric using a hot melt adhesive.

[0005] Based on the above scheme and as a preferred embodiment of the above scheme: the four-axis warp-knitted fabric layer includes a 0° weft layer, a 0° warp layer, a +45° weft layer and a -45° weft layer, which are fixed by binding yarn and arranged sequentially.

[0006] Based on the above scheme and as a preferred embodiment of the above scheme: the binding yarn is high-strength polyester filament; the yarns used in the 0° weft layer, 0° warp layer, +45° weft layer and -45° weft layer include polyester DTY filament.

[0007] Based on the above scheme and as a preferred embodiment of the above scheme: the padding yarn number of the face comb is 1-0 / 0-1 / 1-0 / 1-3 / 3-1 / 1-3 / / , and the yarn threading pattern is full threading; the padding yarn number of the middle comb is 0-0 / 1-1 / 0-0 / 3-3 / 2-2 / 3-3 / / , and the yarn threading pattern is full threading; the padding yarn number of the bottom comb is 2-3 / 1-0 / 2-3 / 1-0 / 2-3 / 1-0 / / , and the yarn threading pattern is full threading.

[0008] Based on the above scheme and as a preferred embodiment of the above scheme: the bio-based hydrophobic thickener is a palm oil thickener.

[0009] Based on the above scheme and as a preferred embodiment of the above scheme: the foamed fabric layer 3 includes a TPU foam layer and a spunlace nonwoven fabric layer.

[0010] Based on the above scheme and as a preferred embodiment of the above scheme: the surface of the spunlace nonwoven fabric layer is coated with an antibacterial and anti-mite agent.

[0011] The beneficial effects of this invention are: the production process of the three-proof sofa fabric involved in this invention utilizes a four-axis warp-knitted fabric layer, which, due to the use of yarns arranged along four axes, enables the sofa fabric to have good tensile strength in multiple directions. Applying a three-proof finishing agent to the polyurethane coating surface can effectively improve the three-proof effect. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of the three-proof sofa fabric prepared by the production process involved in this invention; Figure 2 This is a schematic diagram of the structure of a four-axis warp-knitted fabric layer.

[0013] The markings in the diagram are explained as follows: 1- Suede fabric layer; 2- Four-axis warp-knitted fabric layer; 3- Foamed fabric layer; 21- 0° warp layer; 23- +45° weft layer; 24- -45° weft layer. Detailed Implementation

[0014] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0015] Combine Figure 1 and Figure 2 This embodiment will be described in detail. The production process of a three-proof sofa fabric involved in this embodiment includes the following steps: preparation of suede fabric layer 1, preparation of four-axis warp-knitted fabric layer 2, preparation of foamed fabric layer 3, and fabric lamination.

[0016] The preparation of the suede fabric layer 1 includes weaving, pretreatment, plasma treatment, napping, impregnation with water-based polyurethane solution, first pre-drying, impregnation with nano-crosslinking agent solution, second pre-drying, and spraying with a three-proof finishing agent.

[0017] The suede fabric includes a face comb, a middle comb, and a bottom comb. The yarn used in the face comb is ultra-fine polyester multifilament. The pretreatment refers to immersing the suede fabric in a caustic soda solution, removing it, neutralizing it with acid, and then washing and drying it with clean water.

[0018] Furthermore, the yarn padding numbers of the face comb are 1-0 / 0-1 / 1-0 / 1-3 / 3-1 / 1-3 / / , with a full-length threading pattern; the yarn padding numbers of the middle comb are 0-0 / 1-1 / 0-0 / 3-3 / 2-2 / 3-3 / / , with a full-length threading pattern; and the yarn padding numbers of the bottom comb are 2-3 / 1-0 / 2-3 / 1-0 / 2-3 / 1-0 / / , with a full-length threading pattern. Furthermore, the nylon monofilament used in the middle comb and the polyester DTY filament used in the bottom comb have a diameter of 0.1-0.15 mm. In this embodiment, the polyester DTY filament has a fineness of 50D / 36F. The weight of the prepared suede fabric layer 1 is 220 grams per square meter. The suede fabric is napped on one side of the combed surface and then sheared and combed to make the nap length 1mm.

[0019] The term "pick-up waterborne polyurethane solution" refers to immersing and padding the napped suede fabric in the waterborne polyurethane solution once, with a pick-up rate of 40-50%; in this embodiment, the pick-up rate is 45%.

[0020] The aqueous polyurethane solution comprises 20-30% aqueous polyurethane, 10-15% C16 alkyl polysiloxane, 5-8% nano-zinc oxide particles, 3-5% bio-based hydrophobic thickener, and the balance being water. Specifically, in this embodiment, the aqueous polyurethane solution comprises 25% aqueous polyurethane, 12% C16 alkyl polysiloxane, 6% nano-zinc oxide particles, 4% bio-based hydrophobic thickener, and the balance being water. The bio-based hydrophobic thickener is a palm oil thickener. The specific preparation process involves first adding the aqueous polyurethane, C16 alkyl polysiloxane, and bio-based hydrophobic thickener to water and stirring until homogeneous, then adding the nano-zinc oxide particles and stirring until homogeneous again.

[0021] The first pre-drying is performed at 110-120℃ for 1-3 minutes; in this embodiment, drying at 110℃ for 1 minute is insufficient to completely evaporate the moisture and achieve the desired drying effect. This makes it prone to combining with water-based polyurethane and other reagents during subsequent impregnation with the nano-crosslinking agent solution.

[0022] The padding with the nano-crosslinking agent solution refers to immersing and padding the pre-dried suede fabric in the nano-crosslinking agent solution, with a padding rate of 35-40%, and in this embodiment, the padding rate is 35%. The nano-crosslinking agent solution comprises 10-20% epoxy siloxane, 3-5% nano zinc oxide particles, 3-5% nano titanium dioxide particles, 10-20% glycerol, and 1-2% trisodium citrate; in this embodiment, the nano-crosslinking agent solution comprises 15% epoxy siloxane, 4% nano zinc oxide particles, 4% nano titanium dioxide particles, 15% glycerol, and 2% trisodium citrate. The nano zinc oxide particles added in two stages have good antibacterial effects.

[0023] The second pre-drying refers to drying at 95-100℃ for 1-3 minutes; specifically, in this embodiment, it is drying at 95℃ for 1 minute. After the second pre-drying, the fabric is not completely dry, which is to facilitate the subsequent bonding of the three-proof finishing agent and improve the durability of the three-proof effect.

[0024] The spraying of the three-proof finishing agent refers to spraying a three-proof finishing agent solution onto one side of the nap of the suede fabric after the second pre-drying and then drying it. The three-proof finishing agent solution includes 10-15% three-proof finishing agent, 3-5% easy-to-clean finishing agent DH-302, and 3-5% crosslinking agent. Specifically, in this embodiment, the three-proof finishing agent solution includes 12% three-proof finishing agent, 4% easy-to-clean finishing agent DH-302, and 4% crosslinking agent, with the balance being water. The three-proof finishing agent selected is Huntsman's PHOBOL, and the crosslinking agent is crosslinking agent M90.

[0025] The fabric lamination refers to the bonding of a suede fabric layer, a four-axis warp-knitted fabric layer, and a foamed fabric using hot melt adhesive. Specifically, a hot melt adhesive web is placed between the suede fabric layer and the four-axis warp-knitted fabric layer, and another hot melt adhesive web is placed between the four-axis warp-knitted fabric layer and the foamed fabric layer, and then the bonding is achieved through hot pressing.

[0026] Furthermore, the four-axis warp-knitted fabric layer 2 includes a 0° weft layer 21, a 0° warp layer 22, a +45° weft layer 23, and a -45° weft layer 24, which are fixed by binding yarns and arranged sequentially. The binding yarn is high-strength polyester filament; the yarns used in the 0° weft layer 21, 0° warp layer 22, +45° weft layer 23, and -45° weft layer 24 include polyester DTY filament. The polyester DTY filament is warped and then woven into a four-axis warp-knitted fabric on a warp knitting machine. First, a 0° weft layer 21 is laid on the worktable of the warp knitting machine at a 90° angle to the worktable. Then, a 0° warp layer 22 is covered on top of the 0° weft layer 21 with polyester DTY filament, perpendicular to the yarn direction of the 0° weft layer 21. Then, the +45° weft yarn layer 23 and the -45° weft yarn layer 24 are laid in sequence. High-strength polyester fiber filaments are used as binding yarns and the four yarn layers are warp-knitted into one piece on a warp knitting machine using a chain knitting structure to obtain the greige fabric.

[0027] Furthermore, the foamed fabric layer 3 comprises a TPU foamed layer and a spunlace nonwoven fabric layer laminated together with a hot melt adhesive web. The surface of the spunlace nonwoven fabric layer is coated with an antibacterial and anti-mite agent. The spunlace nonwoven fabric layer used is a flame-retardant polyester spunlace nonwoven fabric.

[0028] Furthermore, the surface of the spunlace nonwoven layer is coated with an antibacterial and anti-mite agent, since the spunlace nonwoven layer is located on the innermost side of the fabric, in order to prevent the growth of bacteria and mites on it.

[0029] The fabric prepared in this embodiment was subjected to a waterproof test using GB / T 4745-2012 as the test standard, and the test result was level 4. Using GB / T 19977 as the test standard, the oil repellency test result was level 5. After 5 washes, the waterproof rating remained level 4, and the oil repellency rating remained level 5. The spunlace nonwoven fabric showed an antibacterial rate of over 95% against Escherichia coli and Staphylococcus aureus. The anti-leech effect was tested according to GB / T 24253, and the test result was 85%.

[0030] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A manufacturing process for a three-proof sofa fabric, characterized in that, The process includes the following steps: preparation of suede fabric layer (1), preparation of four-axis warp-knitted fabric layer (2), preparation of foamed fabric layer (3) and fabric composite; The preparation of the suede fabric layer includes weaving, pretreatment, plasma treatment, napping, impregnation with water-based polyurethane solution, first pre-drying, impregnation with nano crosslinking agent solution, second pre-drying, and spraying with three-proof finishing agent; The suede fabric includes a face comb, a middle comb, and a bottom comb. The yarn used in the face comb is ultra-fine polyester multifilament. The pretreatment refers to immersing the suede fabric in a caustic soda solution, removing it, neutralizing it with acid, and then washing and drying it with clean water. The term "pick-up waterborne polyurethane solution" refers to immersing and padding the napped suede fabric in a waterborne polyurethane solution, with a pick-up rate of 40-50%. The aqueous polyurethane solution comprises 20-30% aqueous polyurethane, 10-15% C16 alkyl polysiloxane, 5-8% nano zinc oxide particles, 3-5% bio-based hydrophobic thickener, and the balance being water. The first pre-drying is performed at 110-120℃ for 1-3 minutes; The padding nano-crosslinking agent solution refers to immersing and padding the pre-dried suede fabric in the nano-crosslinking agent solution once, with a padding rate of 35-40%; the nano-crosslinking agent solution includes 10-20% epoxy siloxane, 3-5% nano zinc oxide particles, 3-5% nano titanium dioxide particles, 10-20% glycerol and 1-2% trisodium citrate; The second pre-drying refers to drying at 95-100℃ for 1-3 minutes; The sprayed three-proof finishing agent refers to spraying a three-proof finishing agent solution onto one side of the nap of the suede fabric after the second pre-drying and then drying it; the three-proof finishing agent solution includes 10-15% three-proof finishing agent, 3-5% easy-to-clean finishing agent DH-302 and 3-5% crosslinking agent; The fabric composite refers to the combination of a suede fabric layer, a four-axis warp-knitted fabric layer, and a foamed fabric using a hot melt adhesive.

2. The manufacturing process of a three-proof sofa fabric according to claim 1, characterized in that, The four-axis warp-knitted fabric layer (2) includes a 0° weft layer (21), a 0° warp layer (22), a +45° weft layer (23), and a -45° weft layer (24) that are fixed by binding yarn and arranged in sequence.

3. The manufacturing process of a three-proof sofa fabric according to claim 2, characterized in that, The binding yarn is high-strength polyester filament; the yarns used in the 0° weft layer (21), 0° warp layer (22), +45° weft layer (23) and -45° weft layer (24) include polyester DTY filament.

4. The manufacturing process of a three-proof sofa fabric according to claim 1, characterized in that, The padding yarn numbers of the face comb are 1-0 / 0-1 / 1-0 / 1-3 / 3-1 / 1-3 / / , and the yarn threading pattern is full threading; the padding yarn numbers of the middle comb are 0-0 / 1-1 / 0-0 / 3-3 / 2-2 / 3-3 / / , and the yarn threading pattern is full threading; the padding yarn numbers of the bottom comb are 2-3 / 1-0 / 2-3 / 1-0 / 2-3 / 1-0 / / , and the yarn threading pattern is full threading.

5. The manufacturing process of a three-proof sofa fabric according to claim 1, characterized in that, The bio-based hydrophobic thickener is a palm oil thickener.

6. The manufacturing process of a three-proof sofa fabric according to claim 1, characterized in that, The foamed fabric layer (3) includes a TPU foam layer and a spunlace nonwoven fabric layer.

7. The manufacturing process of a three-proof sofa fabric according to claim 6, characterized in that, The surface of the spunlace nonwoven fabric layer is coated with an antibacterial and anti-mite agent.

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