Machine washable wool quilt core and production process thereof

Abstract

The invention provides a machine washable wool quilt core and a production process thereof, and the production process comprises the following steps: wool treatment: adopting a chlorination process as a leading technology and combining with a partial biological enzyme treatment technology to effectively peel off scales on the wool surface layer, thereby reducing the entanglement and felting tendencies among wool fibers; wool carding is conducted, specifically, wool fibers are smoothly arranged and fully and naturally cohered through professional wool carding equipment, meanwhile, excessive entanglement is avoided, and the felting phenomenon is further inhibited; the wool quilt core is formed, the needling technology is adopted, interaction among fibers is enhanced in a physical mode, and on the basis that the fluffy performance of the wool quilt core is kept, the structural compactness and the cohesion strength of the wool quilt core are improved. According to the invention, the use of a chemical adhesive and other chemical fiber auxiliary materials is abandoned, and the machine washing resistance of the wool quilt core is obviously improved depending on the natural characteristics of wool. And after machine washing, not only can key indexes such as bulkiness and low wool drilling rate be maintained, but also the wool quilt core returns to natural essence, and the experience feeling is more comfortable.

Description

Technical Field

[0001] This invention relates to the field of wool comforter technology, specifically to a machine-washable wool comforter and its manufacturing process. Background Technology

[0002] The main technical bottleneck in the application of wool comforters lies in their inability to withstand machine washing. This stems from the inherent characteristics of the scale structure on the surface of wool fibers: under the combined action of humid and hot environments and mechanical forces, the scales interlock, causing irreversible directional movement and tight entanglement of the fibers, i.e., felting. This process results in a significant reduction in the thickness of the comforter, an increase in its stiffness, and the appearance of localized clumping, severely affecting its performance and lifespan.

[0003] In existing technologies, wool comforters claiming to be machine washable often rely on blending with synthetic fibers or using large amounts of chemical adhesives to fix the fibers. While these methods can suppress shape changes to some extent, they essentially sacrifice the inherent natural advantages of wool, such as its moisture absorption and warmth retention. They only achieve a superficial and unsustainable "machine wash effect" and do not fundamentally solve the problem of felting and shrinkage of wool fibers.

[0004] Therefore, developing a pure wool comforter core that can withstand multiple industrial machine washes and maintain stable performance while preserving the natural properties of wool has become an urgent technical challenge in this field.

[0005] The biggest drawback of wool comforters is that they cannot be machine washed. This is because the scale structure on the surface of wool fibers is prone to felting and shrinkage under the action of mechanical force, hot water, and detergent, which causes the comforter to clump together, reduce its fluffiness, and affect its service life. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by proposing a machine-washable wool comforter core and its manufacturing process.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a machine-washable wool comforter core, the process comprising the following steps: wool treatment, using a technology dominated by chlorination combined with some biological enzyme treatment to effectively remove the surface scales of wool, thereby reducing the tendency of wool fibers to entangle and felt; wool combing, using professional wool combing equipment to make the wool fibers smoothly arranged and achieve full natural cohesion, while avoiding excessive entanglement and further inhibiting felting; wool comforter core forming, using a needle punching process to strengthen the interaction between fibers through physical means, improving its structural compactness and cohesion strength while maintaining the fluffy performance of the wool comforter core.

[0008] Preferably, the filling density of the machine-washed wool fiber layer is 80-500 g / m², the average length of the wool fibers is 50 mm or more, and the fineness is 26.5 μm or finer.

[0009] Preferably, a chlorination process is used to remove the surface scales of the wool.

[0010] Preferably, a partial bio-enzyme treatment technique is used to effectively remove wool scale residue.

[0011] Preferably, before combing the wool and after opening it, the wool silo should be left to stand still for at least 4 hours to ensure that the moisture is fully and evenly absorbed.

[0012] Preferably, professional wool combing equipment is used, along with matching wool-specific carding cloth, to comb the wool fibers smoothly without damage.

[0013] Preferably, the cross-laying device is rotated 90 degrees to turn and overlap the wool fiber web, eliminating anisotropy and ensuring the mechanical properties and fluffiness and resilience of the formed wool wadding.

[0014] Preferably, two needle punches are combined using two machines to enhance the cohesion between wool fibers and the overall stability of the quilt core.

[0015] Preferably, the entire process, through the precise coordination and interaction of each step, forms a stable processing system, thereby fundamentally ensuring the machine washability of the wool comforter core, allowing it to maintain its shape, structure, and function intact even after multiple machine washes.

[0016] A manufacturing process for a machine-washable wool comforter includes the following steps: S1: Mercerizing of Wool Fibers: Wool fibers are first immersed in a sulfuric acid bath for acidification. After preliminary drying, they are then transferred to a subsequent reaction tank. During this process, the acid adhering to the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby effectively degrading the scale layer. Subsequently, the fibers enter a neutralization tank, where the pH of the system is precisely adjusted to the range of 4.5-6.5 by adding soda ash solution. The neutralized fibers are then thoroughly washed with water and finally dried in a drying oven, ensuring that the moisture regain of the produced wool fibers is stably controlled. After a second washing, the produced wool fibers are placed in the drying oven, maintaining a moisture regain between 15% and 17%. This process can achieve a scale removal rate of over 90% for wool fibers.

[0017] Enzymatic treatment of wool fibers: Place the chlorinated and descaled wool fibers in a treatment tank, add process water at a bath ratio of 1:10, and adjust the pH of the system to 6-8. Then add neutral protease and carry out enzyme treatment at a constant temperature of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the removal of degraded scales.

[0018] After enzyme treatment, the system temperature is raised to above 80°C and maintained for 10-15 minutes. The high-temperature thermal effect completely inactivates the enzyme, thereby precisely terminating the reaction and avoiding excessive damage to the wool fibers.

[0019] The wool fibers are then washed sequentially with hot water and cold water to thoroughly remove any remaining scales and other reaction byproducts. Finally, they are dried to stabilize the moisture regain of the wool fibers within the range of 15%-17%.

[0020] S2: Wool Combing: After mercerizing, the wool fibers are opened and fed into the wool silo. At the same time, an appropriate amount of wool oil and moisture are applied evenly. The wool fibers are then left to stand in the wool silo for at least 4 hours, with the temperature of the wool silo stabilized at 20℃-25℃ and the relative humidity stabilized at 55%-60%, to ensure that the moisture is fully and evenly absorbed. Finally, the overall moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0021] The wool fibers treated as described above are fed into a specialized wool carding machine via a uniform feeding device. Flat-top / ribbon carding cloth with medium or low tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20℃-25℃, with minimizing wool fiber loss as the primary principle.

[0022] The fiber web output from the carding machine is rotated and stacked 90 degrees by a cross-laying device, which effectively eliminates the anisotropy caused by fiber orientation and ensures that the final wool wadding has consistent mechanical properties and fluffy resilience in both the longitudinal and transverse directions.

[0023] S3: A two-stage needle punching process, combining pre-needle punching and main needle punching, is used to gradually reinforce the wool fiber web after it is laid.

[0024] The pre-needling process uses a low needle density (1500-2000 needles / ㎡), a moderate needle depth (3-5mm), and a low needle frequency (100-500 times / minute) to initially entangle the loose and low-initially-strength fiber web, giving it sufficient basic strength to maintain its structure and facilitate subsequent transport and processing.

[0025] The main needle-punching process employs a higher needle density (3000-6000 needles / ㎡), a greater needle-punching depth (over 5mm), and a higher needle-punching frequency (600-1500 times / minute) to deeply and densely entangle the pre-needled wadding. This promotes the full interweaving and cohesion of wool fibers within the three-dimensional shearing process, thereby forming a structurally integrated wadding that ultimately possesses the mechanical properties to withstand machine washing. Preferably, the chlorination process in S1 is as follows: wool fibers are immersed in sulfuric acid for acidification and then guided to a reaction tank. The acid on the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby achieving effective degradation of the scale layer.

[0026] Preferably, the enzyme treatment in S1 is carried out as follows: the wool fibers that have undergone chlorination and descaling are placed in a treatment tank, the pH is adjusted to 6-8 at a bath ratio of 1:10, neutral protease is added, and the enzyme treatment is carried out under constant temperature conditions of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the peeling of degraded scales.

[0027] Preferably, in S2, the mercerized wool fibers that have undergone the opening process are left to stand in a wool silo with a stable temperature of 20℃-25℃ and a stable relative humidity of 55%-60% for no less than 4 hours to ensure that the moisture is fully and evenly absorbed, and finally the moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0028] Preferably, flat-top / ribbon needle cloth and medium or low tooth density needle cloth (500-700 teeth / square inch) are used in S2, and the workshop temperature should be controlled at 20℃-25℃, with the primary principle being to minimize the loss of wool fibers.

[0029] Compared with the prior art, the advantages and positive effects of the present invention are as follows: In this invention, a process combining chlorination and bio-enzyme treatment is used to achieve near-complete removal of the scale layer of wool fibers. This technical approach is significantly different from traditional wool quilts or water-washed wool quilts.

[0030] In subsequent processing, specialized wool combing techniques and optimized comforter forming processes are employed to minimize wool fiber damage and effectively enhance the three-dimensional entanglement and natural cohesion between fibers, thereby endowing the comforter with superior fluffiness and structural integrity. This synergistic effect ultimately enables the wool comforter to withstand multiple machine washes while maintaining its excellent structure and function. Attached Figure Description

[0031] Figure 1 The present invention provides a flowchart of a machine-washable wool comforter core and its manufacturing process. Detailed Implementation

[0032] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other. Example

[0033] Please see Figure 1 This invention proposes a machine-washable wool comforter core, the process of which includes the following steps: wool treatment, using a technology mainly based on chlorination combined with some biological enzyme treatment to effectively remove the surface scales of wool, thereby reducing the tendency of wool fibers to entangle and felt; wool combing, using professional wool combing equipment to make the wool fibers smoothly arranged and achieve full natural cohesion, while avoiding excessive entanglement and further inhibiting felting; wool comforter core forming, using a needle punching process to strengthen the interaction between fibers through physical means, improving its structural compactness and cohesion strength while maintaining the fluffy performance of the wool comforter core.

[0034] The filling density of the wool fiber layer is 260 g / m², the average length of the wool fiber is 50 mm, and the fineness is 26.5 μm. The manufacturing process of machine-washable wool comforters includes the following steps: S1: Mercerizing of Wool Fibers: Wool fibers are first immersed in a sulfuric acid bath for acidification. After preliminary drying, they are then transferred to a subsequent reaction tank. During this process, the acid adhering to the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby effectively degrading the scale layer. Subsequently, the fibers enter a neutralization tank, where the pH of the system is precisely adjusted to the range of 4.5-6.5 by adding soda ash solution. The neutralized fibers are then thoroughly washed with water and finally dried in a drying oven, ensuring that the moisture regain of the produced wool fibers is stably controlled. After a second washing, the produced wool fibers are placed in the drying oven, maintaining a moisture regain between 15% and 17%. This process can achieve a scale removal rate of over 90% for wool fibers.

[0035] Enzymatic treatment of wool fibers: Place the chlorinated and descaled wool fibers in a treatment tank, add process water at a bath ratio of 1:10, and adjust the pH of the system to 6-8. Then add neutral protease and carry out enzyme treatment at a constant temperature of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the removal of degraded scales.

[0036] After enzyme treatment, the system temperature is raised to above 80°C and maintained for 10-15 minutes. The high-temperature thermal effect completely inactivates the enzyme, thereby precisely terminating the reaction and avoiding excessive damage to the wool fibers.

[0037] The wool fibers are then washed sequentially with hot water and cold water to thoroughly remove any remaining scales and other reaction byproducts. Finally, they are dried to stabilize the moisture regain of the wool fibers within the range of 15%-17%.

[0038] S2: Wool Combing: After mercerizing, the wool fibers are opened and fed into the wool silo. At the same time, an appropriate amount of wool oil and moisture are applied evenly. The wool fibers are then left to stand in the wool silo for at least 4 hours, with the temperature of the wool silo stabilized at 20℃-25℃ and the relative humidity stabilized at 55%-60%, to ensure that the moisture is fully and evenly absorbed. Finally, the overall moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0039] The wool fibers treated as described above are fed into a specialized wool carding machine via a uniform feeding device. Flat-top / ribbon carding cloth with medium or low tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20℃-25℃, with minimizing wool fiber loss as the primary principle.

[0040] The fiber web output from the carding machine is rotated and stacked 90 degrees by a cross-laying device, which effectively eliminates the anisotropy caused by fiber orientation and ensures that the final wool wadding has consistent mechanical properties and fluffy resilience in both the longitudinal and transverse directions.

[0041] S3: A two-stage needle punching process, combining pre-needle punching and main needle punching, is used to gradually reinforce the wool fiber web after it is laid.

[0042] The pre-needling process uses a low needle density (1500-2000 needles / ㎡), a moderate needle depth (3-5mm), and a low needle frequency (100-500 times / minute) to initially entangle the loose and low-initially-strength fiber web, giving it sufficient basic strength to maintain its structure and facilitate subsequent transport and processing.

[0043] The main needle punching process uses a higher needle density (3000-6000 needles / ㎡), a greater needle punching depth (more than 5mm), and a higher needle punching frequency (600-1500 times / minute) to deeply and densely entangle the pre-needled wadding, causing the wool fibers to fully interweave and cohede within the three-dimensional wadding, thereby forming a structurally integrated wadding that ultimately possesses mechanical properties resistant to machine washing.

[0044] S4: The molded wool comforter core is sewn and sealed with shrink-proof cotton fabric to make a finished comforter for testing purposes, in order to evaluate various performance aspects.

[0045] After testing, the felting dimensional change rate of the quilt core after 20 machine washes was 0.8% in width and 0.9% in length, with a compression rate of 47.5% and a recovery rate of 95.2%, and the wool's anti-wool-leaking property was qualified. Example

[0046] Please see Figure 1 This invention proposes a machine-washable wool comforter core, the process of which includes the following steps: wool treatment, using a technology mainly based on chlorination combined with some biological enzyme treatment to effectively remove the scales on the surface of the wool, thereby reducing the tendency of wool fibers to entangle and felt; wool combing, using professional wool combing equipment to make the wool fibers smoothly arranged and achieve full natural cohesion, while avoiding excessive entanglement and further inhibiting felting; wool comforter core forming, using a needle punching process to strengthen the interaction between fibers through physical means, while maintaining the fluffy performance of the wool comforter core and improving its structural compactness and cohesion strength.

[0047] The filling density of the wool fiber layer is 260 g / m², the average length of the wool fiber is 50 mm, and the fineness is 26.5 μm. The manufacturing process of machine-washable wool comforters includes the following steps: S1: Mercerizing of Wool Fibers: Wool fibers are first immersed in a sulfuric acid bath for acidification. After preliminary drying, they are then transferred to a subsequent reaction tank. During this process, the acid adhering to the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby effectively degrading the scale layer. Subsequently, the fibers enter a neutralization tank, where the pH of the system is precisely adjusted to the range of 4.5-6.5 by adding soda ash solution. The neutralized fibers are then thoroughly washed with water and finally dried in a drying oven, ensuring that the moisture regain of the produced wool fibers is stably controlled. After a second washing, the produced wool fibers are placed in the drying oven, maintaining a moisture regain between 15% and 17%. This process can achieve a scale removal rate of over 90% for wool fibers.

[0048] Enzymatic treatment of wool fibers: Place the chlorinated and descaled wool fibers in a treatment tank, add process water at a bath ratio of 1:10, and adjust the pH of the system to 6-8. Then add neutral protease and carry out enzyme treatment at a constant temperature of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the removal of degraded scales.

[0049] After enzyme treatment, the system temperature is raised to above 80°C and maintained for 10-15 minutes. The high-temperature thermal effect completely inactivates the enzyme, thereby precisely terminating the reaction and avoiding excessive damage to the wool fibers.

[0050] The wool fibers are then washed sequentially with hot water and cold water to thoroughly remove any remaining scales and other reaction byproducts. Finally, they are dried to stabilize the moisture regain of the wool fibers within the range of 15%-17%.

[0051] S2: Wool Combing: After mercerizing, the wool fibers are opened and fed into the wool silo. At the same time, an appropriate amount of wool oil and moisture are applied evenly. The wool fibers are then left to stand in the wool silo for at least 4 hours, with the temperature of the wool silo stabilized at 20℃-25℃ and the relative humidity stabilized at 55%-60%, to ensure that the moisture is fully and evenly absorbed. Finally, the overall moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0052] The wool fibers treated as described above are fed into a specialized wool carding machine via a uniform feeding device. Flat-top / ribbon carding cloth with medium or low tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20℃-25℃, with minimizing wool fiber loss as the primary principle.

[0053] The fiber web output from the carding machine is rotated and stacked 90 degrees by a cross-laying device, which effectively eliminates the anisotropy caused by fiber orientation and ensures that the final wool wadding has consistent mechanical properties and fluffy resilience in both the longitudinal and transverse directions.

[0054] S3: A two-stage needle punching process, combining pre-needle punching and main needle punching, is used to gradually reinforce the wool fiber web after it is laid.

[0055] The pre-needling process uses a low needle density (1500-2000 needles / ㎡), a moderate needle depth (3-5mm), and a low needle frequency (100-500 times / minute) to initially entangle the loose and low-initially-strength fiber web, giving it sufficient basic strength to maintain its structure and facilitate subsequent transport and processing.

[0056] The main needle punching process uses a higher needle density (3000-6000 needles / ㎡), a greater needle punching depth (more than 5mm), and a higher needle punching frequency (600-1500 times / minute) to deeply and densely entangle the pre-needled wadding, causing the wool fibers to fully interweave and cohede within the three-dimensional wadding, thereby forming a structurally integrated wadding that ultimately possesses mechanical properties resistant to machine washing.

[0057] S4: The molded wool comforter core is sewn and sealed with shrink-proof cotton fabric to make a finished comforter for testing purposes, in order to evaluate various performance aspects.

[0058] After testing, the felting dimensional change rate of the quilt core after 20 machine washes was 0.8% in width and 0.9% in length, with a compression rate of 47.5% and a recovery rate of 95.2%, and the wool's anti-wool-leaking property was qualified. Example

[0059] Please see Figure 1 This invention proposes a machine-washable wool comforter core, the process of which includes the following steps: wool treatment, using a technology mainly based on chlorination combined with some biological enzyme treatment to effectively remove the scales on the surface of the wool, thereby reducing the tendency of wool fibers to entangle and felt; wool combing, using professional wool combing equipment to make the wool fibers smoothly arranged and achieve full natural cohesion, while avoiding excessive entanglement and further inhibiting felting; wool comforter core forming, using a needle punching process to strengthen the interaction between fibers through physical means, while maintaining the fluffy performance of the wool comforter core and improving its structural compactness and cohesion strength.

[0060] The filling density of the wool fiber layer is 170g / ㎡, the average length of the wool fiber is 60mm, and the fineness is 22μm; The manufacturing process of machine-washable wool comforters includes the following steps: S1: Mercerizing of Wool Fibers: Wool fibers are first immersed in a sulfuric acid bath for acidification. After preliminary drying, they are then transferred to a subsequent reaction tank. During this process, the acid adhering to the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby effectively degrading the scale layer. Subsequently, the fibers enter a neutralization tank, where the pH of the system is precisely adjusted to the range of 4.5-6.5 by adding soda ash solution. The neutralized fibers are then thoroughly washed with water and finally dried in a drying oven, ensuring that the moisture regain of the produced wool fibers is stably controlled. After a second washing, the produced wool fibers are placed in the drying oven, maintaining a moisture regain between 15% and 17%. This process can achieve a scale removal rate of over 90% for wool fibers.

[0061] Enzymatic treatment of wool fibers: Place the chlorinated and descaled wool fibers in a treatment tank, add process water at a bath ratio of 1:10, and adjust the pH of the system to 6-8. Then add neutral protease and carry out enzyme treatment at a constant temperature of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the removal of degraded scales.

[0062] After enzyme treatment, the system temperature is raised to above 80°C and maintained for 10-15 minutes. The high-temperature thermal effect completely inactivates the enzyme, thereby precisely terminating the reaction and avoiding excessive damage to the wool fibers.

[0063] The wool fibers are then washed sequentially with hot water and cold water to thoroughly remove any remaining scales and other reaction byproducts. Finally, they are dried to stabilize the moisture regain of the wool fibers within the range of 15%-17%.

[0064] S2: Wool Combing: After mercerizing, the wool fibers are opened and fed into the wool silo. At the same time, an appropriate amount of wool oil and moisture are applied evenly. The wool fibers are then left to stand in the wool silo for at least 4 hours, with the temperature of the wool silo stabilized at 20℃-25℃ and the relative humidity stabilized at 55%-60%, to ensure that the moisture is fully and evenly absorbed. Finally, the overall moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0065] The wool fibers treated as described above are fed into a specialized wool carding machine via a uniform feeding device. Flat-top / ribbon carding cloth with medium or low tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20℃-25℃, with minimizing wool fiber loss as the primary principle.

[0066] The fiber web output from the carding machine is rotated and stacked 90 degrees by a cross-laying device, which effectively eliminates the anisotropy caused by fiber orientation and ensures that the final wool wadding has consistent mechanical properties and fluffy resilience in both the longitudinal and transverse directions.

[0067] S3: A two-stage needle punching process, combining pre-needle punching and main needle punching, is used to gradually reinforce the wool fiber web after it is laid.

[0068] The pre-needling process uses a low needle density (1500-2000 needles / ㎡), a moderate needle depth (3-5mm), and a low needle frequency (100-500 times / minute) to initially entangle the loose and low-initially-strength fiber web, giving it sufficient basic strength to maintain its structure and facilitate subsequent transport and processing.

[0069] The main needle punching process uses a higher needle density (3000-6000 needles / ㎡), a greater needle punching depth (more than 5mm), and a higher needle punching frequency (600-1500 times / minute) to deeply and densely entangle the pre-needled wadding, causing the wool fibers to fully interweave and cohede within the three-dimensional wadding, thereby forming a structurally integrated wadding that ultimately possesses mechanical properties resistant to machine washing.

[0070] S4: The molded wool comforter core is sewn and sealed with shrink-proof cotton fabric to make a finished comforter for testing purposes, in order to evaluate various performance aspects.

[0071] After testing, the quilt core showed that after 20 machine washes, the felting dimensional change rate decreased by 0.5% in width and 1.2% in length, with a compression rate of 46.3% and a recovery rate of 94.1%, and the wool's anti-wool-leaking properties were qualified. Example

[0072] Please see Figure 1 This invention proposes a machine-washable wool comforter core, the process of which includes the following steps: wool treatment, using a technology mainly based on chlorination combined with some biological enzyme treatment to effectively remove the scales on the surface of the wool, thereby reducing the tendency of wool fibers to entangle and felt; wool combing, using professional wool combing equipment to make the wool fibers smoothly arranged and achieve full natural cohesion, while avoiding excessive entanglement and further inhibiting felting; wool comforter core forming, using a needle punching process to strengthen the interaction between fibers through physical means, while maintaining the fluffy performance of the wool comforter core and improving its structural compactness and cohesion strength.

[0073] The filling density of the wool fiber layer is 150g / ㎡, the average length of the wool fiber is 65mm, and the fineness is 17μm; The manufacturing process of machine-washable wool comforters includes the following steps: S1: Mercerizing of Wool Fibers: Wool fibers are first immersed in a sulfuric acid bath for acidification. After preliminary drying, they are then transferred to a subsequent reaction tank. During this process, the acid adhering to the fibers reacts synergistically with sodium hypochlorite in the tank, selectively oxidizing the cystine disulfide bonds in the wool scale structure to sulfanilamide, thereby effectively degrading the scale layer. Subsequently, the fibers enter a neutralization tank, where the pH of the system is precisely adjusted to the range of 4.5-6.5 by adding soda ash solution. The neutralized fibers are then thoroughly washed with water and finally dried in a drying oven, ensuring that the moisture regain of the produced wool fibers is stably controlled. After a second washing, the produced wool fibers are placed in the drying oven, maintaining a moisture regain between 15% and 17%. This process can achieve a scale removal rate of over 90% for wool fibers.

[0074] Enzymatic treatment of wool fibers: Place the chlorinated and descaled wool fibers in a treatment tank, add process water at a bath ratio of 1:10, and adjust the pH of the system to 6-8. Then add neutral protease and carry out enzyme treatment at a constant temperature of 50℃-60℃, with appropriate mechanical stirring to ensure uniform enzymatic reaction and effectively promote the removal of degraded scales.

[0075] After enzyme treatment, the system temperature is raised to above 80°C and maintained for 10-15 minutes. The high-temperature thermal effect completely inactivates the enzyme, thereby precisely terminating the reaction and avoiding excessive damage to the wool fibers.

[0076] The wool fibers are then washed sequentially with hot water and cold water to thoroughly remove any remaining scales and other reaction byproducts. Finally, they are dried to stabilize the moisture regain of the wool fibers within the range of 15%-17%.

[0077] S2: Wool Combing: After mercerizing, the wool fibers are opened and fed into the wool silo. At the same time, an appropriate amount of wool oil and moisture are applied evenly. The wool fibers are then left to stand in the wool silo for at least 4 hours, with the temperature of the wool silo stabilized at 20℃-25℃ and the relative humidity stabilized at 55%-60%, to ensure that the moisture is fully and evenly absorbed. Finally, the overall moisture regain of the wool fibers is precisely controlled within the range of 16.5% to 18.5%.

[0078] The wool fibers treated as described above are fed into a specialized wool carding machine via a uniform feeding device. Flat-top / ribbon carding cloth with medium or low tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20℃-25℃, with minimizing wool fiber loss as the primary principle.

[0079] The fiber web output from the carding machine is rotated and stacked 90 degrees by a cross-laying device, which effectively eliminates the anisotropy caused by fiber orientation and ensures that the final wool wadding has consistent mechanical properties and fluffy resilience in both the longitudinal and transverse directions.

[0080] S3: A two-stage needle punching process, combining pre-needle punching and main needle punching, is used to gradually reinforce the wool fiber web after it is laid.

[0081] The pre-needling process uses a low needle density (1500-2000 needles / ㎡), a moderate needle depth (3-5mm), and a low needle frequency (100-500 times / minute) to initially entangle the loose and low-initially-strength fiber web, giving it sufficient basic strength to maintain its structure and facilitate subsequent transport and processing.

[0082] The main needle punching process uses a higher needle density (3000-6000 needles / ㎡), a greater needle punching depth (more than 5mm), and a higher needle punching frequency (600-1500 times / minute) to deeply and densely entangle the pre-needled wadding, causing the wool fibers to fully interweave and cohede within the three-dimensional wadding, thereby forming a structurally integrated wadding that ultimately possesses mechanical properties resistant to machine washing.

[0083] S4: The molded wool comforter core is sewn and sealed with shrink-proof cotton fabric to make a finished comforter for testing purposes, in order to evaluate various performance aspects.

[0084] After testing, the quilt core showed that after 20 machine washes, the felting dimensional change rate decreased by 1.0% in width and 0.5% in length, with a compression rate of 45.2% and a recovery rate of 93%, and the wool's anti-wool-leaking properties were qualified.

[0085] The above are merely some embodiments of the present invention and are not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments that can be applied to other fields. However, 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 technical solution of this specification shall still fall within the protection scope of the technical solution of the present invention.

Claims

1. A machine washable wool quilt wadding and process for its production characterised in that: The method comprises the following steps: S1-1: wool fiber mercerization treatment: the wool fiber is first immersed in a sulfuric acid tank for acidification treatment, after preliminary drying, it is guided to a subsequent reaction tank, and then the fiber enters a neutralization tank, the system PH is accurately adjusted to the range of 4.5-6.5 by adding a pure alkali solution, the neutralized fiber is washed thoroughly, and finally drying is completed through a drying box; S1-2: wool fiber enzyme treatment: the wool fiber treated by chlorination desquamation is placed in a treatment cylinder, process water is injected at a bath ratio of 1:10, the system PH is adjusted to 6-8, then neutral protease is added, enzyme treatment is carried out under constant temperature conditions of 50-60℃, and moderate mechanical stirring is assisted to ensure uniform enzymatic reaction and effectively promote the peeling of the degraded scales; after the enzyme treatment is completed, the system temperature is raised to above 80℃ and maintained for 10-15 minutes, the enzyme is completely inactivated through high-temperature heat effect, and subsequent hot water washing and cold water washing are carried out to completely remove the peeled scale residues and other reaction byproducts; S2: wool carding: the mercerized wool fiber is opened and sent to a wool bin, is fed into a special wool carding machine through a uniform feeding device, flat / banded needle cloth with medium or lower tooth density (500-700 teeth / square inch) should be selected, and the workshop temperature should be controlled at 20-25℃; the fiber thin web output by the carding machine is turned by 90 degrees and stacked through a cross-laying device, so as to effectively eliminate the anisotropy caused by the directional ordering of the fiber; S3: two needling processes of pre-needling and main needling are adopted to gradually reinforce the laid wool fiber web, the pre-needling process adopts lower needle density (1500-2000 needles / ㎡), moderate needling depth (3-5mm) and lower needling frequency (100-500 times / minute), aiming to preliminarily entangle the fluffy and initially low-strength fiber web, so that it obtains the basic strength required to maintain the structure and smoothly perform subsequent transmission and processing; the main needling process deeply and densely entangles the pre-needled floccus, promotes the wool fibers to fully interweave and hold in the three-dimensional space, thereby forming a structure-integrated floccus, so that it finally has the mechanical properties resistant to machine washing; S4: the formed wool quilt core is sewn and packaged with shrink-resistant cotton cloth to make a finished product quilt for performance evaluation.

2. The machine washable wool comforter core and process for producing the same according to claim 1, characterized in that: The filling density of the wool fiber is 80-500g / ㎡, the average length of the wool fiber is more than 50mm, and the fineness is 26.5μm.

3. The machine washable wool comforter core and process for producing the same according to claim 1, characterized in that: In the step S1, the wool fiber is treated under acidic conditions, so that the effective chlorine molecules in sodium hypochlorite react with the cystine disulfide bond in the wool scale layer to convert it into sulfonamide, thereby realizing effective degradation of the scale and achieving a scale peeling rate of more than 90%.

4. The machine washable wool comforter core and process for producing the same according to claim 1, characterized in that: In the step S2, firstly, the wool fibers are subjected to opening treatment and sent into a wool bin, while a proper amount of oil is uniformly applied and water is supplemented, then the wool fibers are allowed to stand and rest in the wool bin for more than 4 hours, so as to ensure that the water is fully and uniformly absorbed, and finally the overall moisture regain of the wool fibers is accurately controlled in the range of 16.5% to 18.5%.

5. The machine washable wool comforter core and process for producing the same according to claim 1, characterized in that: In the step S3, a two-step needling process combining pre-needling and main needling is adopted to gradually reinforce the wool fiber web after laying, and the main needling process adopts higher needle density (3000-6000 needles / ㎡), larger needling depth (more than 5mm) and higher needling frequency (600-1500 times / minute).

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