High-strength, washable and wear-resistant fabric and manufacturing method thereof

Abstract

The invention discloses a high-strength, washing-resistant and wear-resistant fabric and a manufacturing method thereof. Yarns of the high-strength, washing-resistant and wear-resistant fabric comprise TPI 16.8 / 60S pure cotton yarn and TPI 9.3 / 100D polyester filament yarn. Pure cotton yarn is produced through a combing process; the spinning temperature of 290-298 DEG C, a 96-hole spinneret plate, the spinning speed of 900-1100 m / min, the heat setting temperature of 150-170 DEG C and the heat setting tension of 0.2-0.3 cN / dtex are adopted for producing the polyester filament yarn; woven warp yarns are 100% pure cotton and account for 60% of the total weight of the fabric, weft yarns are 100% polyester fibers and account for 40% of the total weight of the fabric, and the whole fabric is of a four-up and one-down satin weave structure. And the count density is 200 * 100 pieces per inch. The fabric is superior to an existing fabric in multiple indexes such as breaking strength, elongation at break, anti-pilling grade and size washing change rate, is particularly suitable for high-strength and high-frequency industrial washing use scenes such as hotel bed products, and can remarkably prolong the service life and reduce the replacement frequency and washing loss.

Description

Technical Field

[0001] This invention relates to the field of textile manufacturing technology, and in particular to a high-strength, washable, and abrasion-resistant fabric and its manufacturing method. Background Technology

[0002] Hotel guest room linens typically undergo high-frequency industrial washing (washing at temperatures above 75°C, strong alkaline chlorine bleaching, high-speed dehydration, and tunnel drying). However, the bedding fabrics currently used in the hotel industry generally suffer from insufficient strength, pilling, shrinkage, and short lifespan, resulting in high replacement frequency, significant washing losses, and increased operating costs.

[0003] While existing T300 100% cotton fabric (both warp and weft yarns are pure cotton, with an overall satin weave) offers a good feel, its strength and durability are limited. T300 50 / 50 fabric (both warp and weft yarns are 50% cotton and 50% polyester, with an overall plain weave) offers slightly improved durability, but still suffers from poor dimensional stability and pilling. The industry urgently needs a fabric solution that can improve durability while maintaining a comfortable feel.

[0004] Chinese invention patent application CN103643367A discloses a super-simulated cotton jacquard fabric, which is woven from cotton yarn and super-simulated cotton polyester filament on a jacquard loom. The warp yarn is 40-60S cotton yarn, and the weft yarn is 80-100D super-simulated cotton polyester filament. The finished product has a warp density of 500-600 threads / 10cm and a weft density of 120-180 threads / 10cm. It has excellent abrasion resistance and good luster. However, the existing technology still lacks a method to further improve the breaking strength, washability, and abrasion resistance of the fabric by matching the shrinkage rate of the warp and weft yarns, as well as the yarn parameters such as the fineness and twist of the filament. Summary of the Invention

[0005] Due to the aforementioned deficiencies in the existing technology, the present invention first provides a high-strength, washable, and abrasion-resistant fabric and its manufacturing method. By matching the shrinkage rate of the warp and weft yarns, as well as different filament proportions, monofilament fineness, twist, and other filament parameters, the breaking strength, washability, and abrasion resistance of the fabric are further improved.

[0006] To achieve the above objectives, on the one hand, the present invention provides a fabric manufacturing method, including yarn production, weaving, and finishing processes. The produced yarn includes TPI 16.8 / 60S pure cotton yarn and TPI 9.3 / 100D polyester filament. The pure cotton yarn is produced using a combing process. The polyester filament is produced using a spinning temperature of 290~298℃, a 96-hole spinneret, a spinning speed of 900~1100m / min, a heat setting temperature of 150~170℃, and a heat setting tension of 0.2~0.3 cN / dtex.

[0007] The warp yarns are 100% pure cotton, accounting for 60% of the total weight of the fabric, and the weft yarns are 100% polyester fiber, accounting for 40% of the total weight of the fabric. The overall structure is a 4-up-1-down satin weave; the yarn count is 200×100 threads / inch.

[0008] The process parameters for producing polyester filament in the above technical solution give the polyester filament high strength and washability. Simultaneously, the use of 60% cotton yarn reduces the overall shrinkage rate of the fabric. For example, the spinning temperature allows for a single filament strength ≥7.5 cN / dtex, and the spinning speed is higher than the conventional winding speed of 700~800 m / min, allowing the melt to complete orientation and crystallization within 3 cm of the spinneret exit, forming a dual structure of "surface microgrooves + internal microfibers." This improves fiber-fiber cohesion and provides anchor points for finishing, resulting in a fiber slippage rate of <1.5% after 50 washes. The 96-hole spinneret produces a single filament fineness of 1.04 dtex, preserving a soft hand feel while maintaining a stable weft breaking elongation of 30~33%. The heat setting temperature is lower than the traditional 180 ℃, but with a tension of 0.2~0.3 cN / dtex, the polyester achieves low shrinkage memory, with a warp shrinkage of -10% compared to cotton yarn. The complementary shrinkage rates ensure stable finished product dimensions. Meanwhile, the high-twist cotton yarn and combing process result in a hairiness index of <1.2, reducing fiber end exposure during washing; the low-twist polyester filament and high F-number ensure resilience in the weft direction even at 31% elongation, preventing "weft bulging"; and the high density of 200×100 yarns / inch increases the single yarn strength utilization rate to 92%, with a strength retention rate of no less than 90% after 50 washes.

[0009] Furthermore, the steps for producing the polyester filament include:

[0010] S11, polyethylene terephthalate (PET) chips are fed and melted at the spinning temperature;

[0011] S12, Spinning and forming: The uniform melt is quantitatively fed to a 96-hole spinneret and sprayed out at a spinning speed of 900~1100m / min, and then cooled and solidified into filaments.

[0012] S13. Post-spinning treatment: The spun polyester filaments are subjected to hot stretching and heat setting.

[0013] Furthermore, the hot stretching temperature is 70~90 ℃, and the stretching ratio is 2~5 times. Within this window, the polyester grain size increases from 8 nm to 12 nm, the crystallinity increases from 52% to 63%, and the modulus increases by 35%.

[0014] Further, in step S13, the polyester filament is sequentially subjected to hot stretching, mercerizing, heat setting, and anti-pilling treatment; the concentration of the alkali solution used is 180 g / L; the heat setting temperature is 165 ℃; and the resin concentration used in the anti-pilling treatment process is 20 g / L. This three-stage process of mercerizing, heat setting, and anti-pilling treatment forms a cross-linked film on the high-density skeleton, reducing the fiber-fiber friction coefficient and stabilizing the pilling grade to level 4; simultaneously, the resin mechanically interlocks with the polyester microgrooves, achieving the dual indicators of "high strength + washability".

[0015] Furthermore, the fabric undergoes high-strength edge treatment during the weaving process, with 100% polyester fiber added to the edge yarns on both sides, which can improve the fabric's edge resistance to tearing, fraying, and washing.

[0016] Furthermore, the finishing process includes one or more of the following: mercerizing, softening, shaping, anti-pilling, and edge high-strength treatment processes.

[0017] On the other hand, the present invention provides a high-strength, washable, and abrasion-resistant fabric, characterized in that it is produced by the fabric manufacturing method described above; and has a weight of 130 g / m². 2 .

[0018] Furthermore, the breaking strength of the fabric is not less than 850N in the warp direction and not less than 900N in the weft direction.

[0019] Furthermore, the breaking elongation of the fabric is less than 10% in the warp direction and greater than 30% in the weft direction.

[0020] Furthermore, the dimensional change rate of the fabric is no more than -12% in the warp direction and no more than -5% in the weft direction.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] (1) This invention improves the strength and durability of fabrics by optimizing fiber ratio and fabric manufacturing process, while maintaining good touch and breathability. It is suitable for high-frequency washing and long-term compression use environment, and is especially suitable for hotel bedding.

[0023] (2) The fabric of the present invention is superior to existing T300 100% cotton or T300 50 / 50 blended fabrics in terms of multiple indicators such as breaking strength, breaking elongation, anti-pilling grade and dimensional change rate. It is especially suitable for high-intensity and high-frequency industrial washing scenarios, which can significantly extend service life, reduce replacement frequency and washing loss, and improve operational efficiency. Attached Figure Description

[0024] The invention, its features and advantages will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0025] Figure 1 This is a comparison diagram of the radial and weft breaking strength of the fabrics in Embodiment 1 of the present invention and Comparative Examples 1 and 2.

[0026] Figure 2 This is a comparison chart of the anti-pilling test scores of fabrics in Example 1 and Comparative Example 1 of the present invention. Detailed Implementation

[0027] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. It should be understood that all of these exemplary embodiments described are merely some embodiments and examples of the present invention, and not all of them. Rather, these exemplary embodiments are provided so that those skilled in the art can more thoroughly understand the present disclosure and to more completely convey the technical content of the present disclosure to those skilled in the art.

[0028] All monomeric compounds, instruments, testing devices, and reagents used in the following examples are commercially available, and the testing methods employed are existing technologies that can be retrieved. Specifically, the anti-pilling test uses the circular trajectory method of GB / T4802.1. The breaking strength and elongation tests use the strip method of GB / T 3923.1-2013.

[0029] In the following detailed description, numerous specific details are set forth to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that known processes (such as combing processes) are not shown in detail to avoid obscuring the gist of the invention; and that the techniques not detailed in the following effect examples are readily available prior art.

[0030] Example 1

[0031] See Figure 1 This embodiment provides a fabric manufacturing method, including yarn production, weaving, and finishing processes:

[0032] S1. Yarn Production:

[0033] TPI 16.8 / 60S pure cotton yarn is spun using a combing process.

[0034] The steps for spinning TPI 9.3 / 100D polyester filament include:

[0035] S11, PET chips are conveyed and melted at a spinning temperature of 290~298℃; more specifically, the dried PET chips are fed into the screw extruder via a screw conveyor and melted in the barrel through segmented heating.

[0036] S12. Spinning and Forming: The uniform melt is quantitatively fed to a 96-hole spinneret and spun out at a spinning speed of 900~1100 m / min. After cooling and solidification, it is guided to the winding machine by guide rollers. This spinning speed is higher than the conventional winding speed of 700~800 m / min, allowing the melt to complete orientation and crystallization within 3 cm of the spinneret exit, forming a dual structure of "surface microgrooves + internal microfibers". This not only improves fiber-fiber cohesion but also provides anchor points for post-processing, resulting in a fiber slippage rate of <1.5% after 50 washes. The single filament fineness formed by the 96-hole spinneret is 1.04 dtex, which retains a soft hand feel and keeps the weft breaking elongation stable at 30~33%, meeting the high strength and high elasticity recovery requirements of hotel bedding.

[0037] S13. Post-spinning treatment: The spun polyester filaments are subjected to hot stretching and heat setting. The hot stretching temperature is 70~90 ℃, and the stretching ratio is 2~5 times. Within this window, the polyester grain size increases from 8 nm to 12 nm, the crystallinity increases from 52% to 63%, and the modulus increases by 35%. The heat setting temperature is 150~170 ℃, and the heat setting tension is 0.2~0.3 cN / dtex. The heat setting temperature is lower than the traditional 180 ℃, but with a tension of 0.2~0.3 cN / dtex, the polyester achieves low shrinkage memory, which complements the -10% warp shrinkage rate of cotton yarn, ensuring the dimensional stability of the finished product. Furthermore, in step S13, the polyester filaments are sequentially subjected to hot stretching, mercerizing, heat setting, and anti-pilling treatment. The concentration of the mercerizing alkaline solution that can be used is 180 g / L; the heat setting temperature is 165 ℃; and the resin concentration used in the anti-pilling treatment process is 20 g / L.

[0038] S2, Weaving process:

[0039] The fabric is woven on an air-jet loom or rapier loom at a density of 200×100 threads / inch. The warp yarns are made of 100% pure cotton yarn produced above, accounting for 60% of the total weight of the fabric, and the weft yarns are made of 100% polyester fiber yarn produced above, accounting for 40% of the total weight of the fabric. The overall structure is a 4-up-1-down satin weave.

[0040] High-twist cotton yarn and combing process result in a fabric hairiness index of <1.2, reducing fiber end exposure during washing; low-twist polyester filament and high F number ensure that the weft remains elastic even at 31% elongation, avoiding "weft bulging"; high density of 200×100 yarns / inch increases the single yarn strength utilization rate to 92%, and the strength retention rate is not less than 90% after 50 washes.

[0041] To improve the tear resistance, fraying resistance and washability of the fabric edges, 100% polyester fiber can be added to the edge yarns on both sides of the fabric during the weaving process, so that the average number of washes for the entire bedding is ≥150 times.

[0042] S3. Finishing process:

[0043] Fabrics undergo treatments including mercerizing, softening, setting, and anti-pilling to ensure comfort and safety.

[0044] The fabric produced by the above process has the following technical parameters and structure:

[0045] Material composition: 40% polyester fiber, 60% cotton;

[0046] Weaving structure: The warp yarns are 100% pure cotton, and the weft yarns are 100% polyester fiber, with an overall satin weave structure of 4 up and 1 down.

[0047] Yarn parameters: 60S*100D / 96F (S is the abbreviation for English count (Ne), which indicates the fineness of the yarn; D (Denier) indicates the fineness of the yarn; F indicates the number of monofilaments or microfibers that make up this multifilament, i.e., the number of holes in the spinneret during spinning).

[0048] Thread density: 200 x 100 threads / inch;

[0049] Weight: 130 g / m 2 .

[0050] Comparative Example 1

[0051] The fabric provided in this comparative example is the existing T300 100% pure cotton fabric, with both warp and weft yarns being pure cotton, and the overall pattern being satin.

[0052] Comparative Example 2

[0053] The fabric provided in this comparative example is the existing T300 50 / 50 fabric, with both warp and weft yarns being 50% pure cotton and 50% polyester fiber, and the overall pattern being plain weave.

[0054] See Figure 1 , Figure 2 As shown in Table 1, the fabric of Example 1 has good flexibility in the weft direction and is superior to existing mainstream bedding fabrics in terms of breaking strength, pilling resistance and service life (Comparative Examples 1 and 2).

[0055] Table 1. Comparison of fabric performance indicators in Example 1, Comparative Examples 1 and 2

[0056] Performance indicators Example 1 Comparative Example 1 Comparative Example 2 Fracture strength (N) Meridian 873 / Latitude 942 580° Meridian / 574° Latitude Meridian 654 / Latitude 655 Elongation at break Meridian 9.2% / Zonal 31% Meridian 12.1% / Zonal 14.7% Meridian 15.6% / Zonal 12.1% Size change rate Meridian -10.22% / Zonal -3.67% Meridional -6% / Zonal -5.2% Meridian -5.3% / Zonal 0% Anti-pilling grade Overall rating: Level 4 Overall assessment: Level 3 Overall rating: Level 4 pH value 8 7 7

[0057] Compared with existing technologies, this invention provides a high-strength, washable, and wear-resistant fabric and its manufacturing process. The yarn includes TPI 16.8 / 60S pure cotton yarn and TPI 9.3 / 100D polyester filament. The pure cotton yarn is produced using a combing process. The polyester filament is produced using a spinning temperature of 290~298℃, a 96-hole spinneret, a spinning speed of 900~1100m / min, a heat setting temperature of 150~170℃, and a heat setting tension of 0.2~0.3 cN / dtex. The warp yarn is 100% pure cotton, accounting for 60% of the total fabric weight, and the weft yarn is 100% polyester fiber, accounting for 40% of the total fabric weight. The overall weave is a 4-up, 1-down satin weave. The yarn count is 200×100 threads / inch. The fabric outperforms existing fabrics in several indicators, including breaking strength, breaking elongation, anti-pilling grade, and dimensional change rate. It is especially suitable for high-intensity, high-frequency industrial washing applications, such as hotel bedding, and can significantly extend service life and reduce replacement frequency and washing losses.

[0058] The preferred embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and the devices and structures not described in detail should be understood as being implemented in a conventional manner in the art. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the present invention. This does not affect the essential content of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention's technical solutions still fall within the protection scope of the present invention.

Claims

1. A fabric manufacturing method, comprising yarn production, weaving, and finishing processes, characterized in that, The produced yarns include TPI 16.8 / 60S pure cotton yarn and TPI 9.3 / 100D polyester filament; the pure cotton yarn is produced using a combing process; the polyester filament is produced using a spinning temperature of 290~298℃, a 96-hole spinneret, a spinning speed of 900~1100m / min, a heat setting temperature of 150~170℃, and a heat setting tension of 0.2~0.3 cN / dtex; The warp yarns are 100% pure cotton, accounting for 60% of the total weight of the fabric, and the weft yarns are 100% polyester fiber, accounting for 40% of the total weight of the fabric. The overall structure is a 4-up-1-down satin weave; the yarn count is 200×100 threads / inch.

2. The fabric manufacturing method according to claim 1, characterized in that, The steps for producing the polyester filament include: S11, PET chips are conveyed and melted at the spinning temperature; S12, Spinning and forming: The uniform melt is quantitatively fed to a 96-hole spinneret and sprayed out at a spinning speed of 900~1100m / min, then cooled and solidified into filaments; S13. Post-spinning treatment: The spun polyester filaments are subjected to hot stretching and heat setting.

3. The fabric manufacturing method according to claim 2, characterized in that, The temperature for hot stretching is 70~90 ℃, and the stretching ratio is 2~5 times.

4. The fabric manufacturing method according to claim 2, characterized in that, In step S13, the polyester filament is subjected to hot stretching, mercerizing, heat setting, and anti-pilling treatment in sequence; in the mercerizing process, the concentration of the alkali solution used is 180 g / L; the heat setting temperature is 165 ℃; and in the anti-pilling treatment process, the concentration of the resin used is 20 g / L.

5. The fabric manufacturing method according to claim 1, characterized in that, The fabric undergoes edge high-strength treatment during the weaving process.

6. The fabric manufacturing method according to claim 1, characterized in that, The finishing process includes one or more of the following: mercerizing, softening, shaping, and anti-pilling processes.

7. A high-strength, washable, and abrasion-resistant fabric, characterized in that, The fabric is produced by the fabric manufacturing method as described in any one of claims 1 to 6; the weight is 130 g / m². 2 .

8. The high-strength, washable, and abrasion-resistant fabric according to claim 7, characterized in that, The breaking strength of the fabric is not less than 850N in the warp direction and not less than 900N in the weft direction.

9. The high-strength, washable, and abrasion-resistant fabric according to claim 7, characterized in that, The breaking elongation of the fabric is less than 10% in the warp direction and greater than 30% in the weft direction.

10. The high-strength, washable, and abrasion-resistant fabric according to claim 7, characterized in that, The dimensional change rate of the fabric is no more than -12% in the warp direction and no more than -5% in the weft direction.

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