Preparation method of blended hollow super-soft fabric

Abstract

The invention relates to the technical field of textile, and discloses a preparation method of a blended hollow super-soft fabric, which comprises the following steps: raw material blending: mixing alkali-soluble polyester staple fibers and cotton fibers, and then drafting the mixed card slivers by a roving frame; singeing treatment: adopting a double-sided burner singeing machine; desizing treatment: padding the singed fabric in desizing liquid, then padding in bleaching liquid, and then putting the bleached yarn in a mercerizing machine; dyeing and fixing: dyeing by adopting a reactive dye; and softening and shaping: padding a softening agent, then treating the shaped fabric through a rubber blanket preshrinking machine, and then treating the preshrinked fabric through a calender. The long stapled cotton is adopted as the raw material, it is ensured that the blended hollow super-soft fabric has excellent softness and comfort, the high fiber strength and the moderate micronaire value of the long stapled cotton enable the fabric to keep good hand feeling and meanwhile have high durability and tensile resistance, and the fabric is blended with the alkali-soluble polyester staple fiber, so that the fabric is more comfortable to wear and wear. The softness of the fabric is improved.

Description

Technical Field

[0001] This invention relates to the field of textile technology, specifically to a method for preparing a blended hollow ultra-soft fabric. Background Technology

[0002] Blended hollow ultra-soft fabric is a new type of textile material. It refers to a textile fabric that is made by blending cotton fibers with alkali-soluble polyester staple fibers and spinning them, and then undergoing a specific finishing process to form a hollow structure, thereby obtaining an ultra-soft feel and good fluffiness. As consumers' requirements for the quality of textiles increase, traditional pure cotton fabrics can no longer fully meet the market's demand for softness and comfort.

[0003] In traditional hollow yarn preparation methods, cotton fibers are used to coat alkali-soluble polyester filament fibers, which are then dissolved during finishing. However, since the polyester filaments are entirely wrapped around the center of the yarn, a large amount of solvent is required, and incomplete dissolution may occur. Furthermore, although cotton is alkali-resistant but not acid-resistant, excessive use or high alkali concentration can still damage the fibers. To address the current problem of insufficient softness in cotton fabrics, the common method is to add softening oils and other chemical substances. This not only increases costs but may also have environmental and health risks. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a method for preparing blended hollow ultra-soft fabric, which solves the problems of traditional hollow yarn preparation methods that require the use of large amounts of solvents, result in incomplete dissolution, and may damage the fibers, leading to insufficient fabric fluffiness and softness.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for preparing a blended hollow ultra-soft fabric, comprising the following steps: S1. Raw material blending: Alkali-soluble polyester staple fiber and cotton fiber are mixed at a mass ratio of 20-35%:65-80%, and then processed into a blended sliver through cleaning, carding, and drawing processes. S2. Spinning and forming: The mixed raw sliver is drafted to 1.5-2.5 times on a roving frame, and then twisted into yarn on a spinning frame, with the twist coefficient controlled at 350-420; S3. Singeing treatment: A double-sided singeing machine is used, with a flame temperature of 850-950℃, a machine speed of 75-85m / min, and the singeing grade reaches level 4 or above. S4. Desizing treatment: Immerse the singed fabric in desizing solution containing 1-2 g / L amylase and 0.5-1 g / L nonionic surfactant, and leave it for 20-40 minutes. S5. Bleaching treatment: Pad bleaching solution containing 3-5 g / L hydrogen peroxide, 2-3 g / L stabilizer and 2-3 g / L caustic soda, treatment temperature 90-95℃, time 40-60 minutes, pH 10.5-11. S6. Mercerizing and de-fiber removal: Place the bleached yarn in a mercerizing machine and immerse it in a sodium hydroxide solution with a concentration of 80-110g / L. The treatment temperature is 50-70℃ and the time is 25-40 minutes. The alkaline solution is controlled to flow in both directions by a bidirectional circulation pump, and the cotton fiber setting and polyester staple fiber dissolution are completed simultaneously. S7. Dyeing and Fixing: Use reactive dyes for dyeing, with a liquor ratio of 1:10-15, a heating rate of 1.5-2℃ / min, and a dyeing temperature of 60-70℃. During the heat preservation stage, add 20-50g / L of sodium sulfate and 5-15g / L of soda ash. S8. Softening and shaping: Impregnate with a softener containing 8-12% amino silicone oil, with a roll-off rate of 65-75%, a shaping temperature of 130-150℃, and a machine speed of 20-30m / min; S9. Pre-shrink finishing: The shaped fabric is processed by a rubber blanket pre-shrinking machine with a steam pressure of 0.15-0.25MPa and a pre-shrinking rate of 2-4%. S10. Calendering: The pre-shrinked fabric is processed by a calendering machine with a roller surface temperature of 80-100℃, a pressure of 8-12MPa, and a speed of 10-20m / min.

[0006] By adopting the above technical solution—using long-staple cotton as raw material with a micronaire value controlled between 3.8 and 4.5 and a fiber strength reaching or exceeding 28 cN / tex—the blended hollow ultra-soft fabric is ensured to have excellent softness and comfort. The high fiber strength and moderate micronaire value of long-staple cotton enable the fabric to maintain a good hand feel while also possessing high durability and tensile strength. By blending with alkali-soluble polyester staple fiber, not only is the softness of the fabric improved, but the overall performance of the fabric is also enhanced.

[0007] Preferably, the alkali-soluble polyester staple fiber has an alkali-dissolving temperature of 65-75℃, a fiber length of 32-38mm, and a fineness of 1.2-1.8D.

[0008] Preferably, the alkaline solution circulation rate of the mercerizing machine in S6 is 5-8 L / min, the flow direction of the alkaline solution is controlled by a bidirectional circulation pump, and the yarn tension is controlled at 0.8-1.2 cN / tex.

[0009] Preferably, after singeing in S3, a forced cooling process is added, using an air-cooled unit to cool the yarn. The cold air temperature is 10-25℃, the wind speed is 8-12m / s, and the cooling time is 8-12 seconds.

[0010] Preferably, after S7 staining, a gradient cooling process is used. In the first stage, the temperature is reduced from 80℃ to 60℃ at a rate of 0.5-1℃ / min. In the second stage, the temperature is reduced to 50℃ at a rate of 0.3-0.5℃ / min. Then, the surface dye is removed by washing with water in a counter-current flow at a speed of 3-5 m / min. 3 / h.

[0011] Preferably, the cotton fiber is long-staple cotton with a micronaire value of 3.8-4.5 and a fiber strength ≥28cN / tex.

[0012] Preferably, the S8 softener contains 2-4% anionic penetrant and 1-3% nonionic antistatic agent. When adjusting the pH value, a mixed solution of acetic acid and sodium citrate is used with a mass ratio of 1:0.5-1 to adjust the pH value to 5.5-6.5.

[0013] Preferably, in the spinning machine process of S2, the front roller speed is 180-220 r / min, the rear roller speed is 1.1-1.3 times the front roller speed, and the width of the nip spacer block is 2.0-3.0 mm.

[0014] Preferably, the yarn treated with S6 is vacuum dewatered, with the vacuum gauge pressure of the dewatering machine being -0.06 to -0.08 MPa and the dewatering time being 3-8 minutes. After dewatering, the moisture content is monitored online by an infrared moisture meter to be 12-18%.

[0015] Preferably, in S7, the gap between the compression rollers of the rubber blanket pre-shrinking machine is 0.5-1.2mm, the blanket surface temperature is 110-130℃, and the fabric passing speed is 10-15m / min. In S10, the calender adopts a three-roll vertical structure, with the upper roller being a mirror steel roller, the middle roller being a wool paper roller, and the lower roller being a rubber roller.

[0016] This invention provides a method for preparing a blended hollow super-soft fabric. It has the following beneficial effects: 1. In this invention, long-staple cotton is used as raw material, with its micronaire value controlled between 3.8 and 4.5 and fiber strength reaching or exceeding 28 cN / tex. This ensures that the blended hollow ultra-soft fabric has excellent softness and comfort. The high fiber strength and moderate micronaire value of long-staple cotton enable the fabric to maintain a good hand feel while also possessing high durability and tensile strength. By blending with alkali-soluble polyester staple fiber, not only is the softness of the fabric improved, but the overall performance of the fabric is also enhanced.

[0017] 2. In this invention, the dyed fabric is treated with a gradient cooling process. In the first stage, the temperature is reduced from 80℃ to 60℃ at a rate of 0.5-1℃ / min, and in the second stage, the temperature is reduced to 50℃ at a rate of 0.3-0.5℃ / min. This effectively improves the uniformity of dyeing and color fastness. This precise temperature control helps dye molecules penetrate and fix more evenly on the fibers, reducing color difference and color spots. At the same time, it enhances the color fastness of the fabric, making the blended hollow ultra-soft fabric more stable and durable in color performance.

[0018] 3. In this invention, the yarn after mercerizing and de-fiber treatment is vacuum dehydrated. The vacuum gauge pressure of the dehydrator is controlled at -0.06 to -0.08 MPa, and the dehydration time is 3-8 minutes. After dehydration, the moisture content is monitored online by an infrared moisture meter to 12-18%, ensuring that the moisture content of the fabric is suitable. This improves the dimensional stability and wrinkle resistance of the fabric. The suitable moisture content helps to maintain the softness and processability of the fabric, reducing dimensional changes and wrinkles caused by too much or too little moisture. This makes the blended hollow ultra-soft fabric smoother and more comfortable to wear and use. Attached Figure Description

[0019] Figure 1 This is a flowchart of a method for preparing a blended hollow super-soft fabric according to the present invention; Figure 2 This is a schematic diagram of a blended hollow ultra-soft fabric produced by the present invention using a scanning electron microscope (SEM). Detailed Implementation

[0020] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see the appendix Figure 1 This invention provides a method for preparing a blended hollow super-soft fabric, comprising the following steps: S1, raw material blending: alkali-soluble polyester staple fiber and cotton fiber are mixed at a mass ratio of 20-35%:65-80%, and then processed through cotton cleaning, carding, and drawing processes to produce a blended sliver; S2. Spinning and forming: The mixed raw sliver is drafted to 1.5-2.5 times on a roving frame, and then twisted into yarn on a spinning frame, with the twist coefficient controlled at 350-420; S3. Singeing treatment: A double-sided singeing machine is used, with a flame temperature of 850-950℃, a machine speed of 75-85m / min, and the singeing grade reaches level 4 or above. S4. Desizing treatment: Immerse the singed fabric in desizing solution containing 1-2 g / L amylase and 0.5-1 g / L nonionic surfactant, and leave it for 20-40 minutes. S5. Bleaching treatment: Pad bleaching solution containing 3-5 g / L hydrogen peroxide, 2-3 g / L stabilizer and 2-3 g / L caustic soda, treatment temperature 90-95℃, time 40-60 minutes, pH 10.5-11. S6. Mercerizing and de-fiber removal: Place the bleached yarn in a mercerizing machine and immerse it in a sodium hydroxide solution with a concentration of 80-110g / L. The treatment temperature is 50-70℃ and the time is 25-40 minutes. The alkaline solution is controlled to flow in both directions by a bidirectional circulation pump, and the cotton fiber setting and polyester staple fiber dissolution are completed simultaneously. S7. Dyeing and Fixing: Use reactive dyes for dyeing, with a liquor ratio of 1:10-15, a heating rate of 1.5-2℃ / min, and a dyeing temperature of 60-70℃. During the heat preservation stage, add 20-50g / L of sodium sulfate and 5-15g / L of soda ash. S8. Softening and shaping: Impregnate with a softener containing 8-12% amino silicone oil, with a roll-off rate of 65-75%, a shaping temperature of 130-150℃, and a machine speed of 20-30m / min; S9. Pre-shrink finishing: The shaped fabric is processed by a rubber blanket pre-shrinking machine with a steam pressure of 0.15-0.25MPa and a pre-shrinking rate of 2-4%. S10. Calendering: The pre-shrinked fabric is processed by a calendering machine with a roller surface temperature of 80-100℃, a pressure of 8-12MPa, and a speed of 10-20m / min.

[0022] Specifically, in the raw material blending Please see the appendix Figure 1 The alkali-soluble polyester staple fiber has an alkali-soluble temperature of 65-75℃, a fiber length of 32-38mm, and a fineness of 1.2-1.8D.

[0023] Specifically, by mixing alkali-soluble polyester staple fiber with cotton fiber at a mass ratio of 20-35%:65-80%, the strength of polyester and the softness of cotton can be balanced, while providing a foundation for the subsequent alkali-soluble process. In the spinning process, drafting on a roving frame and twisting on a spinning frame create yarn with a certain twist, providing the basic material for weaving. Singeing treatment uses high-temperature flames to remove short fibers and fuzz from the yarn surface, making the fabric surface smoother and reducing pilling. Desizing treatment uses a desizing solution containing amylase and nonionic surfactants to effectively remove sizing from the yarn, improving its absorbency and dyeing uniformity. Bleaching treatment uses hydrogen peroxide and caustic soda to remove pigments from the yarn, resulting in a uniform fabric. The white color enhances the dyeing effect; mercerizing involves treating the yarn in a sodium hydroxide solution to enhance the luster of the cotton fibers and improve their hand feel, while simultaneously dissolving polyester staple fibers to form a hollow structure, improving the fabric's warmth and breathability; reactive dyes are used to dye the fabric in the dyeing and fixing process, and by controlling the dyeing temperature and adding auxiliaries such as sodium sulfate and soda ash, the uniformity of dyeing and color fastness are improved; softening and setting involves padding with a softener containing amino silicone oil to improve the fabric's softness and hand feel, enhancing wearing comfort; pre-shrinking is achieved through a rubber blanket pre-shrinking machine, which pre-shrinks the fabric under humid and hot conditions, reducing shrinkage during subsequent use; calendering is performed using a calendering machine to make the fabric surface smoother and shinier, improving the fabric's appearance quality.

[0024] Please see the appendix Figure 1 In the S6 mercerizing machine, the alkaline solution circulation rate is 5-8 L / min, and a bidirectional circulation pump is used to control the flow direction of the alkaline solution. The yarn tension is controlled at 0.8-1.2 cN / tex.

[0025] Specifically, treating yarn in sodium hydroxide solution enhances the luster and improves the hand feel of cotton fibers, while dissolving polyester staple fibers to form a hollow structure. By adjusting the alkali solution circulation speed and a bidirectional circulation pump, the contact efficiency between the alkali solution and the yarn is improved, shortening the processing time and increasing production efficiency.

[0026] Please see the appendix Figure 1 After singeing in S3, a forced cooling process is added, using an air-cooled unit to cool the yarn. The cold air temperature is 10-25℃, the wind speed is 8-12m / s, and the cooling time is 8-12 seconds.

[0027] Specifically, rapid cooling can reduce the risk of heat damage to the yarn after singeing due to high temperature, thus protecting the yarn quality. By controlling the cooling time and air speed, excessive shrinkage of the yarn due to rapid cooling can be avoided, which in turn affects subsequent processing and fabric dimensional stability.

[0028] Please see the appendix Figure 1After S7 staining, a gradient cooling process is used. In the first stage, the temperature is reduced from 80℃ to 60℃ at a rate of 0.5-1℃ / min. In the second stage, the temperature is reduced to 50℃ at a rate of 0.3-0.5℃ / min. Then, the surface dye is removed by washing with water in a counter-current flow at a speed of 3-5m / min. 3 / h.

[0029] Specifically, by controlling the rate of temperature reduction after dyeing, the dye can be more evenly fixed on the fiber, reducing color fastness problems caused by rapid temperature changes. Gradual cooling helps the dye to be evenly distributed on the fiber, reducing color difference and color spots.

[0030] Please see the appendix Figure 1 The cotton fiber is long-staple cotton with a micronaire value of 3.8-4.5 and a fiber strength of ≥28cN / tex.

[0031] Specifically, the micronaire value is an important indicator for measuring the maturity and quality of cotton fibers. It reflects the fineness and maturity of cotton fibers. A micronaire value of 3.8-4.5 indicates that the cotton fibers have good maturity and moderate fineness, which gives long-staple cotton good luster, softness and spinning performance. A moderate micronaire value is beneficial to improving the uniformity and strength of yarn, reducing the breakage rate during the spinning process and improving production efficiency.

[0032] Please see the appendix Figure 1 S8 softener contains 2-4% anionic penetrant and 1-3% nonionic antistatic agent. When adjusting the pH value, a mixed solution of acetic acid and sodium citrate is used with a mass ratio of 1:0.5-1 to adjust the pH value to 5.5-6.5.

[0033] Specifically, the addition of amino silicone oil significantly improves the softness and smoothness of the fabric, making it more skin-friendly and comfortable; the addition of anionic penetrants improves the fabric's permeability, allowing the softener to better penetrate into the fibers, improving the uniformity and durability of the softening effect; the addition of nonionic antistatic agents reduces static electricity in the fabric, improving wearing comfort, especially in dry environments; and a near-neutral pH value helps maintain the fabric's softness and feel while reducing potential irritation to the fabric and skin, improving the fabric's durability and wearing experience.

[0034] Please see the appendix Figure 1 In the S2 spinning machine process, the front roller speed is 180-220 r / min, the rear roller speed is 1.1-1.3 times the front roller speed, and the width of the nip spacer is 2.0-3.0 mm.

[0035] Specifically, the spinning frame uses drafting and twisting to give the yarn appropriate twist and strength, while maintaining the yarn's uniformity and consistency. By adjusting the front roller speed, the yarn draft ratio can be controlled to achieve the required yarn fineness and strength. The appropriate multiple of the rear roller speed ensures the synchronization between the front and rear rollers, avoiding yarn quality problems caused by uneven drafting. The appropriate width of the nip spacer helps maintain fiber parallelism and yarn uniformity, reducing fiber entanglement and unevenness in the yarn.

[0036] Please see the appendix Figure 1 After S6 treatment, the yarn is vacuum dewatered. The vacuum gauge pressure of the dewatering machine is -0.06 to -0.08 MPa, and the dewatering time is 3-8 minutes. After dewatering, the moisture content is monitored online by an infrared moisture meter to be 12-18%.

[0037] Specifically, vacuum dehydration can quickly remove moisture from the yarn, and online monitoring ensures that the moisture content is controlled within the optimal range. A suitable moisture content helps maintain the softness and processability of the yarn, thereby improving the quality of the yarn.

[0038] Please see the appendix Figure 1 In S7, the compression roller gap of the rubber blanket pre-shrinking machine is 0.5-1.2mm, the blanket surface temperature is 110-130℃, and the fabric passing speed is 10-15m / min. In S10, the calender adopts a three-roll vertical structure, with the upper roller being a mirror steel roller, the middle roller being a wool paper roller, and the lower roller being a rubber roller.

[0039] Specifically, pre-shrinking helps eliminate internal stress in the fabric, reduces dimensional changes caused by temperature and humidity variations, and improves the fabric's smoothness and appearance quality; calendering helps compact fabric fibers, reduce bulk, and improve the fabric's gloss and abrasion resistance. Mirror steel rollers provide a high-gloss calendering effect, suitable for fabrics requiring a high-gloss surface treatment; wool paper rollers provide a soft calendering effect while reducing damage to the fabric; and rubber rollers provide a uniform pressure distribution, ensuring consistent calendering results.

[0040] Example 1 I. Technical Solution 1. Raw material blending: Alkali-soluble polyester staple fiber (30%) is blended with long-staple cotton (70%). Alkali-soluble polyester parameters: alkali soluble temperature 70℃, fiber length 35mm, fineness 1.5D; cotton fiber micronaire value 4.2, strength 30cN / tex.

[0041] 2. Spinning and forming: roving draft 2.0 times, front roller of the spinning machine 200r / min, back roller 220r / min (speed ratio 1.1), twist coefficient 380.

[0042] 3. Singeing treatment: Double-sided singeing machine, flame temperature 900℃, machine speed 80m / min, the fabric surface is free of lint after singeing.

[0043] 4. Desizing treatment: Impregnate with desizing solution (amylase 1.5g / L + nonionic surfactant 0.8g / L) and let stand for 30 minutes.

[0044] 5. Bleaching treatment: 4 g / L hydrogen peroxide, 2.5 g / L stabilizer, 2.5 g / L caustic soda, temperature 92℃, time 50 minutes, pH 10.8.

[0045] 6. Mercerizing and de-fiber removal: Sodium hydroxide concentration 95g / L, temperature 60℃, time 30 minutes, alkali solution circulation flow rate 6L / min, yarn tension 1.0cN / tex.

[0046] 7. Dyeing and Fixation: Dyeing with reactive dyes, heating rate 1.8℃ / min, dyeing temperature 65℃, sodium sulfate 35g / L, soda ash 10g / L.

[0047] 8. Softening and shaping: 10% amino silicone oil + 3% anionic penetrant + 2% nonionic antistatic agent, pH 6.0, shaping temperature 140℃, machine speed 25m / min.

[0048] 9. Pre-shrink finishing: Rubber blanket pre-shrinking machine, steam pressure 0.2MPa, pre-shrinking rate 3%.

[0049] 10. Calendering and finishing: Three-roll calender (mirror steel roll / wool paper roll / rubber roll), roll temperature 90℃, pressure 10MPa, machine speed 15m / min.

[0050] 2. Experimental Results Test items Example 1 Standard fabric (commercially available pure cotton) Test standards Breathability (mm / s) 320 280 GB / T5453 Shrinkage rate (%) 1.8 5.2 GB / T8629 Softness (mN) 45 75 GB / T8942 Summary: Example 1, through the blending of alkali-soluble polyester and long-staple cotton, combined with an optimized mercerizing and de-fiber process, significantly improved breathability (+14%) and reduced shrinkage (-65%), and the softness was superior to conventional pure cotton fabrics.

[0051] Example 2 I. Technical Solution 1. Raw material blending: Adjusted to a blend of alkali-soluble polyester staple fiber (35%) and long-staple cotton (65%). Alkali-soluble polyester parameters: alkali-soluble temperature 65℃, fiber length 38mm, fineness 1.8D; cotton fiber micronaire value 4.2, strength 30cN / tex.

[0052] 2. Spinning and forming: Same as in Example 1, with roving draft of 2.0 times, front roller of the spinning machine at 200 r / min, back roller at 220 r / min (speed ratio 1.1), and twist coefficient of 380.

[0053] 3. Singeing treatment: Same as in Example 1, using a double-sided singeing machine with a flame temperature of 900℃ and a machine speed of 80m / min. After singeing, the fabric surface is free of lint.

[0054] 4. Desizing treatment: Adjust the dosage of nonionic surfactant to 1.2 g / L and let it stand for 40 minutes.

[0055] 5. Bleaching treatment: Same as in Example 1, with 4 g / L hydrogen peroxide, 2.5 g / L stabilizer, and 2.5 g / L caustic soda, at a temperature of 92°C for 50 minutes, and a pH of 10.8.

[0056] 6. Mercerizing and de-fiber removal: Same as in Example 1, with sodium hydroxide concentration of 95 g / L, temperature of 60°C, time of 30 minutes, alkali solution circulation flow rate of 6 L / min, and yarn tension of 1.0 cN / tex.

[0057] 7. Dyeing and fixing: Adjust the dyeing temperature to 70℃, use 50g / L sodium sulfate and 15g / L soda ash.

[0058] 8. Softening and shaping: Same as in Example 1, 10% amino silicone oil + 3% anionic penetrant + 2% nonionic antistatic agent, pH 6.0, shaping temperature 140℃, machine speed 25m / min.

[0059] 9. Pre-shrink finishing: Same as in Example 1, rubber blanket pre-shrinking machine, steam pressure 0.2MPa, pre-shrinking rate 3%.

[0060] 10. Finishing: Adjust the pressure to 12MPa, and the rest is the same as in Example 1 (roll temperature 90℃, machine speed 15m / min).

[0061] II. Verification of Technical Effects Test items Example 2 Example 1 Test standards Fracture strength (N) 520 480 GB / T3923.1-2013 Color fastness to rubbing (grade) 4-5 4 GB / T3920-2008 In summary: Increasing the proportion of alkali-soluble polyester to 35% and optimizing the dyeing temperature improved the breaking strength by 8% and the color fastness by 0.5 grades, making it suitable for high-strength applications; the unadjusted singeing, mercerizing, and other processes ensured the stability of the hollow structure and air permeability (air permeability 335 mm / s, close to Example 1).

[0062] Example 3 I. Technical Solution 1. Raw material blending: Adjusted to a blend of alkali-soluble polyester staple fiber (20%) and long-staple cotton (80%). Alkali-soluble polyester parameters: alkali-soluble temperature 75℃, fiber length 32mm, fineness 1.2D; cotton fiber micronaire value 4.2, strength 30cN / tex.

[0063] 2. Spinning and forming: Same as in Example 1, with roving draft of 2.0 times, front roller of the spinning machine at 200 r / min, back roller at 220 r / min (speed ratio 1.1), and twist coefficient of 380.

[0064] 3. Singeing treatment: Same as in Example 1, using a double-sided singeing machine with a flame temperature of 900℃ and a machine speed of 80m / min. After singeing, the fabric surface is free of lint.

[0065] 4. Desizing treatment: Same as in Example 1, soak in desizing solution (amylase 1.5g / L + nonionic surfactant 0.8g / L), and let stand for 30 minutes.

[0066] 5. Bleaching treatment: Same as in Example 1, with 4 g / L hydrogen peroxide, 2.5 g / L stabilizer, and 2.5 g / L caustic soda, at a temperature of 92°C for 50 minutes, and a pH of 10.8.

[0067] 6. Mercerizing and fiber removal: Adjust the sodium hydroxide concentration to 110g / L and extend the time to 40 minutes.

[0068] 7. Dyeing and fixing: Same as in Example 1, using reactive dyes, heating rate 1.8℃ / min, dyeing temperature 65℃, sodium sulfate 35g / L, soda ash 10g / L.

[0069] 8. Softening and shaping: Same as in Example 1, 10% amino silicone oil + 3% anionic penetrant + 2% nonionic antistatic agent, pH 6.0, shaping temperature 140℃, machine speed 25m / min.

[0070] 9. Pre-shrinking finishing: Adjust the pre-shrinking rate to 4% and the steam pressure to 0.25MPa.

[0071] 10. Finishing: Same as in Example 1, with roller temperature of 90℃, pressure of 10MPa, and machine speed of 15m / min.

[0072] II. Verification of Technical Effects Test items Example 3 Comparative example (without antistatic agent) Test standards Rebound rate (%) 88 72 GB / T18318 Electrostatic half-life (s) 0.8 3.5 GB / T12703 In summary: reducing the proportion of alkali-soluble polyester to 20% and strengthening mercerizing and desizing improved resilience by 22% and significantly enhanced antistatic properties compared to the control group without antistatic agents; the unadjusted desizing and dyeing processes ensured dyeing uniformity (color fastness grade 4, consistent with Example 1).

[0073] Comparative Example 1 (Traditional Polyester-Cotton Blend) I. Technical Solution: Use ordinary polyester (non-alkali soluble) and cotton fiber (30%:70%), skip the mercerizing and defiber removal step, and directly set the shape after dyeing.

[0074] II. Test Results: Test items Comparative Example 1 Example 1 Test standards Hollow structure retention rate none 92％ FZ / T01101-2008 Breathability (mm / s) 250 320 GB / T5453-1997 In summary: The fabric lacks a hollow structure due to the absence of alkali-soluble polyester and the omission of mercerizing and fiber removal, resulting in a 28% reduction in breathability.

[0075] Comparative Example 2 (desizing treatment omitted) I. Technical Solution: Skip the desizing step and proceed directly to bleaching; other processes are the same as in Example 1.

[0076] Test results: Test items Comparative Example 2 Example 1 Test standards Capillary effect (cm / 30min) 4.2 8.5 GB / T21655.1-2008 Dyeing uniformity Partial color patterns uniform GB / T22798-2019 In conclusion, failure to desizing resulted in a 50% reduction in capillary efficiency and poor dyeing uniformity, demonstrating the necessity of desizing treatment for subsequent dyeing.

[0077] Summary of Experimental Data: Test items Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Breathability (mm / s) 320 335 305 250 290 Shrinkage rate (%) 1.8 1.5 2.0 5.2 3.8 Fracture strength (N) 480 520 460 430 450 Hollow structure retention rate (%) 92 90 85 0 88 in conclusion: The three embodiments of the present invention, by adjusting the alkali-soluble polyester ratio and process parameters (such as desizing time and mercerizing alkali concentration), verified the flexibility of the technical solution, and demonstrated this through comparative examples: 1. The synergistic effect of alkali-soluble polyester and mercerized defiber is the key to forming a hollow structure; 2. Desizing treatment and gradient cooling process significantly improve dyeing uniformity; 3. The three-roll calender structure (mirror steel roll + wool paper roll) optimizes the gloss and softness of the fabric.

[0078] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a blended hollow ultra-soft fabric, characterized in that, Includes the following steps: S1. Raw material blending: Alkali-soluble polyester staple fiber and cotton fiber are mixed at a mass ratio of 20-35%:65-80%, and then processed into a blended sliver through cleaning, carding, and drawing processes. S2. Spinning and forming: The mixed raw sliver is drafted to 1.5-2.5 times on a roving frame, and then twisted into yarn on a spinning frame, with the twist coefficient controlled at 350-420; S3. Singeing treatment: A double-sided singeing machine is used, with a flame temperature of 850-950℃, a machine speed of 75-85m / min, and the singeing grade reaches level 4 or above. S4. Desizing treatment: Immerse the singed fabric in desizing solution containing 1-2 g / L amylase and 0.5-1 g / L nonionic surfactant, and leave it for 20-40 minutes. S5. Bleaching treatment: Pad bleaching solution containing 3-5 g / L hydrogen peroxide, 2-3 g / L stabilizer and 2-3 g / L caustic soda, treatment temperature 90-95℃, time 40-60 minutes, pH 10.5-11. S6. Mercerizing and de-fiber removal: Place the bleached yarn in a mercerizing machine and immerse it in a sodium hydroxide solution with a concentration of 80-110g / L. The treatment temperature is 50-70℃ and the time is 25-40 minutes. The alkaline solution is controlled to flow in both directions by a bidirectional circulation pump, and the cotton fiber setting and polyester staple fiber dissolution are completed simultaneously. S7. Dyeing and Fixing: Use reactive dyes for dyeing, with a liquor ratio of 1:10-15, a heating rate of 1.5-2℃ / min, and a dyeing temperature of 60-70℃. During the heat preservation stage, add 20-50g / L of sodium sulfate and 5-15g / L of soda ash. S8. Softening and shaping: Impregnate with a softener containing 8-12% amino silicone oil, with a roll-off rate of 65-75%, a shaping temperature of 130-150℃, and a machine speed of 20-30m / min; S9. Pre-shrink finishing: The shaped fabric is treated with a rubber blanket pre-shrinking machine with a steam pressure of 0.15-0.25MPa and a pre-shrinking rate of 2-4%. S10. Calendering: The pre-shrinked fabric is processed by a calendering machine with a roller surface temperature of 80-100℃, a pressure of 8-12MPa, and a speed of 10-20m / min.

2. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, The alkali-soluble polyester staple fiber has an alkali-dissolving temperature of 65-75℃, a fiber length of 32-38mm, and a fineness of 1.2-1.8D.

3. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, The alkaline solution circulation rate of the mercerizing machine in S6 is 5-8 L / min. A bidirectional circulation pump is used to control the flow direction of the alkaline solution, and the yarn tension is controlled at 0.8-1.2 cN / tex.

4. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, After singeing, the S3 yarn undergoes a forced cooling process, using an air-cooled unit to cool the yarn. The air temperature is 10-25℃, the wind speed is 8-12m / s, and the cooling time is 8-12 seconds.

5. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, After S7 staining, a gradient cooling process is used. In the first stage, the temperature is reduced from 80℃ to 60℃ at a rate of 0.5-1℃ / min. In the second stage, the temperature is reduced to 50℃ at a rate of 0.3-0.5℃ / min. Then, the surface color is removed by washing with water in a counter-current flow at a flow rate of 3-5 m³ / h.

6. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, The cotton fiber is long-staple cotton with a micronaire value of 3.8-4.5 and a fiber strength of ≥28cN / tex.

7. The method for preparing a blended hollow super-soft fabric according to claim 1, characterized in that, S8 fabric softener contains 2-4% anionic penetrant and 1-3% nonionic antistatic agent. When adjusting the pH value, a mixed solution of acetic acid and sodium citrate is used with a mass ratio of 1:0.5-1 to adjust the pH value to 5.5-6.

5.

8. The method for preparing a blended hollow super-soft fabric according to claim 1, characterized in that, In the S2 spinning machine process, the front roller speed is 180-220 r / min, the rear roller speed is 1.1-1.3 times that of the front roller, and the width of the nip spacer is 2.0-3.0 mm.

9. The method for preparing a blended hollow super-soft fabric according to claim 1, characterized in that, After S6 treatment, the yarn is vacuum dewatered. The vacuum gauge pressure of the dewatering machine is -0.06 to -0.08 MPa, and the dewatering time is 3-8 minutes. After dewatering, the moisture content is monitored online by an infrared moisture meter to be 12-18%.

10. The method for preparing a blended hollow ultra-soft fabric according to claim 1, characterized in that, The compression roller gap of the rubber blanket pre-shrinking machine in S7 is 0.5-1.2mm, the blanket surface temperature is 110-130℃, and the fabric throughput speed is 10-15m / min. The calender in S10 adopts a three-roll vertical structure, with the upper roller being a mirror steel roller, the middle roller being a wool paper roller, and the lower roller being a rubber roller.

Images