Tatting ultra-high water absorption fabric and production process thereof

Abstract

The fabric is of a five-layer structure formed by interweaving warp yarn and weft yarn, and the five-layer structure sequentially comprises a surface layer water absorption layer, a surface layer base layer, a middle water retention layer, an inner layer base layer and an inner layer water absorption layer from outside to inside; warp yarns of the fabric comprise surface warp yarns and inner warp yarns, and weft yarns comprise surface weft yarns, inner weft yarns and connecting weft yarns. The surface warps and the surface wefts are interwoven to form a surface base layer of the fabric, and the inner warps and the inner wefts are interwoven to form an inner base layer of the fabric; the surface of the surface base layer and the surface of the inner base layer are provided with fiber fluff structures to form a surface water absorption layer and an inner water absorption layer respectively; the connecting weft yarns shuttle between the surface warps and the inner warps, are interwoven into connecting points, and prop open the surface base layer and the inner base layer, so that a three-dimensional cavity is formed between the surface base layer and the inner base layer, and a middle water retention layer is formed. The fabric is formed by integral weaving, and through the multi-layer structure, ultrahigh water absorption is achieved, and the defects that a traditional water absorption fabric is prone to hair slip and snagging are overcome.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and in particular to a woven ultra-absorbent fabric and its production process. Background Technology

[0002] Currently, in pursuit of superior water absorption performance, the textile industry mainly explores two dimensions: fiber raw material innovation and fabric structure design, resulting in representative technological approaches. These approaches each have their own focus in improving fabric water absorption, but their inherent performance limitations are gradually becoming apparent in practical applications. These limitations can be summarized into the following three categories: The first type is woven double-sided napped fabric. This type of fabric typically uses polyester-nylon composite microfiber yarn, utilizing the specific surface area advantage of microfiber and a napping process to create a napped surface, achieving a water absorption rate of approximately 300%. However, its structure is essentially a dense single-layer or solid double-layer structure, relying on the capillary effect of the fibers themselves and the water storage capacity of the napped surface, thus limiting its water absorption capacity. Furthermore, since the nap is obtained by abrading the surface of the base fabric, the length and strength of the nap are limited, and long-term use and washing may lead to shedding and wear on the napped surface, resulting in a decrease in water absorption performance.

[0003] The second category is knitted long-pile fabrics such as coral fleece. These products also mostly use polyester-nylon composite yarns and are knitted to form long pile, utilizing the large fiber loft to store water, thus resulting in a high water absorption rate. However, their main drawbacks are: firstly, the knitted structure or the long-pile structure after cutting the pile is extremely prone to shedding and pilling due to friction and snagging during use, affecting the appearance and user experience; secondly, their long-pile structure is also more likely to tangle and flatten after washing, leading to poor appearance and a stiffer feel.

[0004] The third category is woven or knitted fabrics with a terry loop structure. These fabrics increase water retention by forming loops, and the raw material can be cotton or polyester / nylon microfiber. While the terry loop structure provides extra water-holding space, its prominent loops are very prone to snagging or even breaking under external force. Once snagged, it not only severely affects the appearance but also damages the uniformity and absorbency of the loops. This is a significant drawback for applications that prioritize durability and aesthetics.

[0005] In summary, existing superabsorbent fabric technologies often struggle to balance durability, dimensional stability, and appearance retention when pursuing higher absorbency. Specifically, woven napped fabrics relying on single-fiber capillary absorption encounter limitations in absorbency; while superabsorbent fabrics relying on a fluffy nap or terry loop structure generally suffer from issues such as easy shedding, snagging, and difficulty in maintaining their appearance after washing. Therefore, the market urgently needs a new type of fabric that can overcome existing structural limitations, achieving ultra-high absorbency while effectively overcoming defects such as shedding and snagging. Summary of the Invention

[0006] To address the aforementioned technical problems, the present invention aims to provide a woven ultra-high absorbency fabric and its manufacturing process. The fabric of the present invention achieves an ultra-high absorbency rate of over 800% by integrally weaving a five-layer structure with three-dimensional cavities, while overcoming the technical defects of traditional high absorbency fabrics such as easy shedding and snagging.

[0007] To achieve the above-mentioned technical objectives and effects, the present invention is implemented through the following technical solution: The present invention provides a woven super absorbent fabric, which has a five-layer structure made of warp and weft yarns, from the outside to the inside as follows: surface absorbent layer, surface base layer, middle water-retaining layer, inner base layer and inner absorbent layer; The fabric has warp yarns including outer warp and inner warp, and weft yarns including outer weft, inner weft, and connecting weft yarns. The outer warp and outer weft interweave to form the outer base layer of the fabric, and the inner warp and inner weft interweave to form the inner base layer of the fabric. The surfaces of the outer base layer and the inner base layer both have a fibrous pile structure, which respectively constitute the outer absorbent layer and the inner absorbent layer. The connecting weft yarns shuttle between the outer warp and the inner warp, interweave to form connection points, and spread the outer base layer and the inner base layer apart to form a three-dimensional cavity between them, which constitutes the intermediate water-retaining layer.

[0008] In a preferred embodiment of the present invention, both the outer base layer and the inner base layer are made of microfiber yarn, and the outer absorbent layer is formed by a surface roughening process of the outer base layer, and the inner absorbent layer is formed by a surface roughening process of the inner base layer.

[0009] As another preferred embodiment of the present invention, both the outer base layer and the inner base layer are made of fancy yarns, and the fiber pile structure is formed by the pile carried by the fancy yarns constituting the outer base layer and the inner base layer.

[0010] Preferably, the connecting weft yarn is a fancy yarn.

[0011] More preferably, the microfiber yarn is a polyester-nylon composite microfiber yarn.

[0012] Furthermore, one circular weave unit of the fabric consists of 128 warp yarns and 6 weft yarns; wherein the ratio of the number of front warp yarns to the number of back warp yarns is 1:1, and the ratio of the number of front weft yarns, back weft yarns, and connecting weft yarns is 1:1:1.

[0013] Furthermore, the outer warp and outer weft interweave to form a plain weave structure, and the inner warp and inner weft interweave to form a plain weave structure.

[0014] Another aspect of the present invention provides a production process for woven ultra-absorbent fabric, comprising the following steps: Step 1: Design the organizational structure; Step 2: Prepare warp and weft yarns: Warp yarns include outer warp and inner warp, and weft yarns include outer weft, inner weft, and connecting weft yarns; Step 3, Weaving: After warping, the outer warp and outer weft are interwoven according to the weave structure design to form the outer base layer, and the inner warp and inner weft are interwoven according to the weave structure design to form the inner base layer; the connecting weft yarns shuttle between the outer and inner warp, interweaving to form the connection point, and the outer base layer and inner base layer are stretched to form the middle water-retaining layer, thus obtaining the greige fabric; the greige fabric is selectively napped according to the yarn raw materials of the outer base layer and inner base layer (i.e., napped or not napped) to obtain the woven ultra-high absorbency fabric; the woven ultra-high absorbency fabric includes, from the outside to the inside, an outer absorbent layer, an outer base layer, a middle water-retaining layer, an inner base layer, and an inner absorbent layer.

[0015] Furthermore, in the above production process, when both the outer base layer and the inner base layer are made of microfiber yarn, the outer base layer and the inner base layer of the woven fabric are respectively subjected to a napping process to form the outer absorbent layer and the inner absorbent layer. When both the outer and inner base layers are made of fancy yarns, no napping is performed. The fiber fluff structure carried by the fancy yarns themselves constitutes the outer and inner absorbent layers. Preferably, in the above production process, the connecting weft yarn is a fancy yarn.

[0016] The beneficial effects of this invention are as follows: (1) Achieving ultra-high water absorption and efficient water retention: The "three-dimensional cavity" (intermediate water-retaining layer) formed by the connecting weft yarns creates a stable water storage space inside the fabric that does not directly bear external forces, significantly increasing the fabric's water-holding capacity. Combined with the "double-layer water-absorbing network" (surface water-absorbing layer and inner water-absorbing layer) of the surface and inner layers, it can quickly absorb water through a strong capillary effect and transfer it to the intermediate water-retaining layer for storage. This synergistic structure of "rapid double-sided water-absorbing layer + three-dimensional water-retaining cavity" enables the fabric to achieve an ultra-high water absorption rate as a whole.

[0017] (2) Significantly improves durability and overcomes the defect of easy snagging: The water absorption function of the fabric is mainly achieved through the internal intermediate water-retaining layer and the double-sided water-absorbing layer. Its surface base layer and inner base layer are both woven base layers with strong interlacing points, and the surface water-absorbing layer and inner water-absorbing layer are both dense pile surfaces formed on the woven base layer. Compared with traditional fabrics that rely on protruding loops or long piles to store water, this structure does not have loose long piles or loops that are easily hooked by external forces, so it can avoid the problem of "snagging" and greatly improve the durability and appearance of the fabric.

[0018] (3) Effectively reduces shedding and improves quality stability: The outer and inner absorbent layers of the fabric are formed by napping the sturdy woven base layer with microfiber yarns or by using the fiber pile structure carried by the yarn itself. The pile originates from some fibers of the base layer yarn and is tightly connected to the base layer yarn body, resulting in a stable structure. Compared with coral fleece and other fabrics that cut the yarn or form a long and loose pile structure, the pile of the fabric structure of this invention is denser and has stronger adhesion, so it is not easy to fall off during use and washing, effectively overcoming the problem of traditional absorbent fabrics easily "shedding".

[0019] (4) Integrated structure with stable and reliable performance: The five-layer functional structure of the fabric of this invention is formed by weaving warp and weft yarns in one step. Through the design of the structure, the connecting weft yarns not only form cavities, but also connect the surface structure and the inner structure into a whole. This integrated structure ensures that the functional layers are firmly bonded and not easily delaminated, and the middle water-retaining layer has good structural stability, making the fabric's ultra-high water absorption performance and overall mechanical properties more durable and reliable. Attached Figure Description

[0020] Figure 1 This is a pattern diagram for the fabric weaving process of the present invention.

[0021] Figure 2 This is a structural diagram of the fabric of the present invention. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0023] Example 1 The production process of the woven ultra-absorbent fabric in Example 1 includes the following steps: Step 1: Design the fabric structure. One repeating unit of the fabric is woven from 128 warp yarns and 6 weft yarns. The warp yarns are divided into front warp and back warp, arranged in a 1:1 ratio. The weft yarns include front weft, back weft, and connecting weft yarns, with a quantity ratio of 1:1:1, and the arrangement order is: front weft, back weft, front weft, back weft, connecting weft yarn, connecting weft yarn.

[0024] Step 2: Prepare warp and weft yarns: The outer warp and weft yarns are made of 160D / 72F*8-lobed polyester-nylon composite microfiber yarn. The inner warp and weft yarns are made of the same 160D / 72F*8-lobed polyester-nylon composite microfiber filament as the outer warp and weft yarns. The connecting weft yarn is made of 4.5NM chenille fancy yarn.

[0025] Step 3: On-machine manufacturing: First, the core basis of weaving is Figure 1 The diagram shown illustrates the pattern. This diagram specifies the rising and falling pattern of each heald frame (corresponding to each column) as each weft yarn (corresponding to each row in the diagram) is introduced within a complete weft weave cycle, thus determining the interlacing relationship between the warp and weft yarns. Figure 1 In the diagram, 1, 3, 5, and 7 represent the outer warp, 2, 4, 6, and 8 represent the inner warp, I represents the outer weft, II represents the inner weft, and III represents the connecting weft yarn. Furthermore, Figure 1 In the diagram, ■ indicates the weaving point where the outer warp is above, × indicates the weaving point where the inner warp is above, ○ indicates the interlacing connection between the outer warp and the connecting weft yarn, and △ indicates the interlacing connection between the inner warp and the connecting weft yarn.

[0026] The fabric is woven on a double-beam rapier loom. The outer and inner warps are warped separately on two warp beams and controlled with different tensions to facilitate the formation of a clear outer and inner layer. Heddle threading, reed insertion, and programming are performed according to the weave pattern and the designed weave diagram. The heddle threading pattern is as follows: (1, 2, 3, 4)*7, 1, 2, 5, 4, (1, 2, 3, 4)*7, 1, 2, 3, 6, (1, 2, 3, 4)*7, 1, 2, 3, 7, (1, 2, 3, 4)*7, 1, 2, 8, 4; After warping, the fabric is woven according to the weave pattern and the weaving diagram. During weaving, the outer warp and weft interweave in a plain weave pattern to form a dense and smooth outer base layer. Simultaneously, the inner warp and weft interweave in a plain weave pattern to form the inner base layer. Connecting weft yarns interweave alternately with the outer and inner warp yarns according to the design, forming connection points. Because the connecting weft yarns themselves have a certain stiffness and bulkiness, and their interweaving points with the outer and inner base layers are carefully designed to be staggered, the connecting weft yarns follow a wavy or arched path in the fabric's thickness direction. This effectively separates the outer and inner base layers, forming a stable, porous three-dimensional cavity between them. This cavity constitutes the fabric's intermediate moisture-retaining layer.

[0027] Step 4: Fabric Nailing Treatment: The woven fabric undergoes double-sided napping. Using a wire napping machine, the front (corresponding to the outer base layer) and back (corresponding to the inner base layer) of the fabric are appropriately napped. The napping process pulls out and breaks some of the microfibers in the polyester-nylon composite microfiber yarn, forming a dense, soft layer of short fibers on the surfaces of the outer and inner base layers, thus constituting the outer and inner absorbent layers. The napping process parameters must be precisely controlled to ensure the nap is full and strong, avoiding excessive napping that could damage the base layer structure.

[0028] In subsequent processes, the fabric can be subjected to conventional post-treatments such as shaping, as needed.

[0029] like Figure 2 As shown, the fabric obtained by the present invention has a five-layer structure: from the outside to the inside, it consists of a surface absorbent layer 10 (fiber pile structure, i.e., a superfine fiber pile layer formed by napping), a surface base layer 20 (polyester-nylon superfine fiber plain weave structure layer), an intermediate water-retaining layer 30 (a three-dimensional cavity supported by 4.5NM chenille fancy yarn), an inner base layer (polyester-nylon superfine fiber plain weave structure layer) 40, and an inner absorbent layer 50 (fiber pile structure, i.e., a superfine fiber pile layer formed by napping).

[0030] The fabric provided in Example 1 has a dense, soft, short pile on both the outer and inner layers, and the pile is full and strong. The fabric has undergone a water absorption test, and its water absorption rate can reach over 800%.

[0031] Example 2 The main difference between Example 2 and Example 1 is that the outer warp, inner warp, outer weft, and inner weft use 15NM chenille fancy yarn. After the greige fabric is woven, it is not napped. Otherwise, it is the same as Example 1.

[0032] The fabric provided in Example 2 has a full, uniform, and strong pile, high bonding strength with the base layer, and is not prone to shedding. The fabric is generally fluffy, thick, and soft, and its water absorption rate can also reach over 800%.

[0033] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0034] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A woven ultra-absorbent fabric, characterized in that, The fabric has a five-layer structure made of interwoven warp and weft yarns, which are, from the outside to the inside: surface absorbent layer, surface base layer, middle water-retaining layer, inner base layer and inner absorbent layer. The fabric has warp yarns including outer warp and inner warp, and weft yarns including outer weft, inner weft, and connecting weft yarns. The outer warp and outer weft interweave to form the outer base layer of the fabric, and the inner warp and inner weft interweave to form the inner base layer of the fabric. The surfaces of the outer base layer and the inner base layer both have a fibrous pile structure, which respectively constitute the outer absorbent layer and the inner absorbent layer. The connecting weft yarns shuttle between the outer warp and the inner warp, interweave to form connection points, and spread the outer base layer and the inner base layer apart to form a three-dimensional cavity between them, which constitutes the intermediate water-retaining layer.

2. The woven ultra-absorbent fabric according to claim 1, characterized in that, Both the outer and inner base layers are made of microfiber yarn. The outer absorbent layer is formed by applying a surface roughening process to the outer base layer, and the inner absorbent layer is formed by applying a surface roughening process to the inner base layer.

3. The woven ultra-absorbent fabric according to claim 1, characterized in that, Both the outer and inner base layers are made of fancy yarns, and the fiber pile structure is formed by the pile carried by the fancy yarns that make up the outer and inner base layers.

4. The woven ultra-absorbent fabric according to claim 1, characterized in that, The connecting weft yarn is a fancy yarn.

5. The woven ultra-absorbent fabric according to claim 2, characterized in that, The microfiber yarn is a polyester-nylon composite microfiber yarn.

6. The woven ultra-absorbent fabric according to claim 1, characterized in that, One repeating unit of the fabric consists of 128 warp yarns and 6 weft yarns; wherein the ratio of the number of front warp yarns to the number of back warp yarns is 1:1, and the ratio of the number of front weft yarns, back weft yarns, and connecting weft yarns is 1:1:

1.

7. The woven ultra-absorbent fabric according to claim 1 or 6, characterized in that, The outer warp and outer weft interweave to form a plain weave structure, and the inner warp and inner weft interweave to form a plain weave structure.

8. A production process for a woven ultra-absorbent fabric as described in any one of claims 1 to 7, characterized in that, Includes the following steps: Step 1: Design the organizational structure; Step 2: Prepare warp and weft yarns: Warp yarns include outer warp and inner warp, and weft yarns include outer weft, inner weft, and connecting weft yarns; Step 3, Weaving on the loom: After warping, the outer warp and outer weft are interwoven according to the weave structure design to form the outer base layer, and the inner warp and inner weft are interwoven according to the weave structure design to form the inner base layer; The connecting weft yarns shuttle between the outer and inner warp, interlacing to form connection points, and stretching the outer base layer and inner base layer to form an intermediate water-retaining layer, thus obtaining the greige fabric; the woven greige fabric is selectively napped according to the yarn raw materials of the outer base layer and inner base layer to obtain the woven ultra-high absorbency fabric; the woven ultra-high absorbency fabric includes an outer absorbent layer, an outer base layer, an intermediate water-retaining layer, an inner base layer, and an inner absorbent layer arranged sequentially from the outside to the inside.

9. The production process of the woven ultra-absorbent fabric according to claim 8, characterized in that, When both the outer and inner base layers are made of microfiber yarn, the outer and inner base layers of the woven fabric are respectively subjected to a napping process to form the outer absorbent layer and the inner absorbent layer. When both the outer and inner base layers are made of fancy yarns, no napping process is performed. The fiber fluff structure carried by the fancy yarn itself constitutes the outer and inner absorbent layers.

10. The production process of the woven ultra-absorbent fabric according to claim 8, characterized in that, The connecting weft yarn is a fancy yarn.

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