Manufacturing method of sound insulation jacquard curtain

Abstract

The invention discloses a sound insulation jacquard curtain manufacturing method, and relates to the technical field of household textiles. Comprising the following steps: preparing a woven fabric layer, namely desizing, boiling and bleaching one of high-count and high-density pure cotton and blended fabric, and performing pre-shrinking treatment to obtain a base fabric layer; and a sound insulation layer is prepared, specifically, gradient density composite fiber felt is adopted, and the sound insulation layer is obtained through three fiber layers from bottom to top. Through the arrangement of the sound insulation layer, a fiber network forms countless tiny gaps, sound waves are converted into heat energy due to air friction and viscous resistance after entering, the sound insulation layer adopts the upper, middle and lower layers of fiber nets with different densities and materials, a gradient structure is formed, sound waves with different frequencies can be effectively absorbed and attenuated, the lower layer deals with low frequency, and the sound insulation layer can effectively absorb and attenuate sound waves with different frequencies. The middle layer treats intermediate frequency, and the upper layer treats high frequency, so that full-band efficient sound insulation is realized.

Description

Technical Field

[0001] This invention relates to the field of home textile technology, specifically a method for manufacturing soundproof jacquard curtains. Background Technology

[0002] With the acceleration of urbanization and the increasing demand for comfortable living environments, indoor acoustics are receiving more and more attention. Noise pollution from road traffic and neighborhood activities seriously affects residents' rest and quality of life. As an essential soft decoration for the home, curtains have evolved from simple light blocking and decoration to multifunctionality.

[0003] However, existing curtains, when used in scenarios that pursue high-end decorative aesthetics, often have drawbacks. These include a narrow sound insulation spectrum, poor blocking of mid-to-low frequency noise, a heavy overall appearance with limited effectiveness, difficulty in balancing decorative appeal (especially three-dimensionality) and sound insulation, and the tendency for delamination and deformation due to washing or gravity after prolonged use, affecting both lifespan and appearance. Therefore, we propose a more convenient and practical sound-insulating jacquard curtain to meet these needs. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing soundproof jacquard curtains to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for manufacturing soundproof jacquard curtains, comprising the following steps:

[0006] Step 1: Fabric layer preparation. One of the following fabrics is used: high-count, high-density pure cotton or blended fabric. After desizing, boiling, and bleaching, it undergoes pre-shrinking treatment to obtain the base fabric layer.

[0007] Step 2: Sound insulation layer preparation. Gradient density composite fiber felt is used, which consists of three fiber layers from bottom to top to obtain the sound insulation layer.

[0008] Step 3: Jacquard surface preparation. Warp yarn: bicomponent composite yarn; weft yarn: heterogeneous shrinkage blended yarn. Using an electronic jacquard machine, a raised and recessed jacquard pattern is designed. The three-dimensional effect of the pattern is enhanced by the difference in float length between the warp and weft yarns, thus obtaining the jacquard surface.

[0009] Step 4, multi-layer composite processing: spray water-based environmentally friendly adhesive evenly on the back of the base fabric layer, and stack the sound insulation layer and the glued base fabric layer together. At the same time, apply adhesive to the other side of the sound insulation layer as well, and then perform hot pressing composite through a flatbed hot press to obtain the curtain fabric.

[0010] Step 5: Production and Inspection. According to the size specifications of the curtains, use a computer-controlled automatic cutting machine to cut them. Use double-needle or triple-thread binding to sew the edges together. Make a hook bag at the top of the curtains and sew lead thread into the side and bottom edges. Install curtain hooks and Velcro. At the same time, conduct sound insulation tests, appearance inspections, size measurements, and peel strength tests to obtain the soundproof jacquard curtains.

[0011] Furthermore, the pre-shrinking treatment is performed using a mechanical pre-shrinking machine at a temperature of 80-100℃ for 10-20 minutes.

[0012] Furthermore, the fiber layer comprises, from bottom to top, an upper layer, a middle layer, and a lower layer;

[0013] The upper layer is a fiber web formed by mixing and combing low-melting-point polyester fibers and hollow glass microspheres;

[0014] The middle layer is a blend of conventional polyester fibers and nano-silica aerogel, combed into a middle layer fiber web;

[0015] The lower layer is a blend of highly crimped viscose fibers and short flax fibers, combed into a lower fiber web;

[0016] The three-layer fiber web is bonded together by hot air to form a gradient density structure.

[0017] Furthermore, the areal density of the gradient density composite fiber felt is 200-500 g / m². 2 The thickness ratio of the three-layer fiber web is upper layer: middle layer: lower layer = 1:1.5:1.

[0018] Furthermore, the upper fiber web contains low-melting-point polyester fibers with a melting point of 120-140℃ and hollow glass microspheres with a particle size of 10-50μm; the middle fiber web contains nano-silica aerogel particles with a particle size of 20-100nm; and the lower fiber web contains flax staple fibers with a length of 10-30mm.

[0019] Furthermore, the bicomponent composite yarn is a PET / PTT parallel composite fiber, and the heteroshrunk blended yarn is a blend of cationic dyeable polyester and ordinary polyester, with a blending ratio of 1:1.5.

[0020] Furthermore, the water-based environmentally friendly adhesive is an acrylic adhesive with a viscosity of 1000-3000 mPa·s. During hot pressing, the temperature of the flatbed hot press is controlled at 120-150℃, the pressure is 2-5 MPa, and the hot pressing time is 3-5 minutes.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] This method for manufacturing soundproof jacquard curtains utilizes a soundproof layer. The fiber network itself forms countless tiny gaps, and when sound waves enter, they are converted into heat energy due to air friction and viscous resistance. The soundproof layer uses three layers of fiber networks with different densities and materials to form a gradient structure, which can effectively absorb and attenuate sound waves of different frequencies. The lower layer deals with low frequencies, the middle layer deals with mid frequencies, and the upper layer deals with high frequencies, thereby achieving efficient sound insulation across the entire frequency range. It is highly practical and suitable for widespread application.

[0023] At the same time, by precisely controlling the float length of the warp and weft yarns, a textured pattern is formed, creating a strong three-dimensional effect that is both visually and tactilely appealing, and the quality far surpasses that of ordinary printed or embroidered curtains. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0025] This invention provides a technical solution: a method for manufacturing soundproof jacquard curtains, comprising the following steps: Step 1: Fabric layer preparation. High-count, high-density pure cotton and blended fabrics are used. After desizing, boiling and bleaching, pre-shrinking treatment is carried out to obtain the base fabric layer. The pre-shrinking treatment is carried out using a mechanical pre-shrinking machine. The treatment temperature is 80-100℃ and the time is 10-20 minutes. Step 2: Sound insulation layer preparation. Gradient density composite fiber felt is used, which consists of three fiber layers from bottom to top to form a sound insulation layer. The fiber layers include an upper layer, a middle layer, and a lower layer from bottom to top. The upper layer is a fiber web formed by mixing and combing low-melting-point polyester fibers and hollow glass microspheres; The middle layer is a blend of conventional polyester fibers and nano-silica aerogel, combed into a middle layer fiber web; The lower layer is a blend of highly crimped viscose fibers and short flax fibers, combed into a lower fiber web; The three-layer fiber web is bonded together by hot air to form a gradient density structure.

[0032] The areal density of gradient density composite fiber felt is 200-500 g / m². 2 The thickness ratio of the three-layer fiber web is upper layer: middle layer: lower layer = 1:1.5:1.

[0033] The upper fiber web contains low-melting-point polyester fibers with a melting point of 120-140℃ and hollow glass microspheres with a particle size of 10-50μm; the middle fiber web contains nano-silica aerogel particles with a particle size of 20-100nm; and the lower fiber web contains flax staple fibers with a length of 10-30mm.

[0034] Step 3: Jacquard surface layer preparation. Warp yarn: bicomponent composite yarn; weft yarn: heteroshrunk blended yarn. Using an electronic jacquard machine, a raised and recessed jacquard pattern is designed. The three-dimensional effect of the pattern is enhanced by the difference in float length between the warp and weft yarns to obtain the jacquard surface layer. The bicomponent composite yarn is a PET / PTT parallel composite fiber, and the heteroshrunk blended yarn is a blend of cationic dyeable polyester and ordinary polyester with a blending ratio of 1:1.5.

[0035] Step four, multi-layer composite processing: uniformly spray water-based environmentally friendly adhesive onto the back of the base fabric layer, and then stack the sound insulation layer and the glued base fabric layer together. At the same time, the other side of the sound insulation layer is also coated with adhesive, and then hot-pressed together using a flatbed hot press to obtain the curtain fabric. The water-based environmentally friendly adhesive is an acrylic adhesive with a viscosity of 1000-3000 mPa·s. During hot-pressing, the temperature of the flatbed hot press is controlled at 120-150℃, the pressure is 2-5 MPa, and the hot-pressing time is 3-5 minutes.

[0036] Step 5: Production and Inspection. According to the size specifications of the curtains, use a computer-controlled automatic cutting machine to cut them. Use double-needle or triple-thread binding to sew the edges together. Make a hook bag at the top of the curtains and sew lead thread into the side and bottom edges. Install curtain hooks and Velcro. At the same time, conduct sound insulation tests, appearance inspections, size measurements, and peel strength tests to obtain the soundproof jacquard curtains.

[0037] Example 1: Standard soundproof jacquard curtains

[0038] step:

[0039] Fabric layer: 60-count high-density pure cotton fabric is used. After desizing, scouring and bleaching, it is mechanically pre-shrinked at 90℃ for 15 minutes.

[0040] Sound insulation layer: Lower fiber web: High-curvature viscose fiber and 20mm long flax staple fiber are mixed and carded in a 70 / 30 ratio; Middle fiber web: Conventional polyester fiber is mixed and carded with 40nm nano-silica aerogel (15%); Upper fiber web: Low-melting-point polyester fiber with a melting point of 130℃ is mixed and carded with 30μm hollow glass microspheres (20%). The three fiber webs are stacked in a thickness ratio of 1:1.5:1 and hot-air bonded at 135℃ to produce a surface density of 300g / m². 2 Gradient density composite fiber felt.

[0041] Jacquard surface layer: The warp yarns are made of PET / PTT parallel composite fibers, and the weft yarns are made of a blend of cationic dyeable polyester and ordinary polyester in a ratio of 1:1.5, which are woven into geometric relief patterns on an electronic jacquard machine.

[0042] Composite processing: A water-based acrylic adhesive with a viscosity of approximately 2000 mPa·s is uniformly sprayed onto the back of the base fabric layer. After being laminated with the sound insulation layer, the adhesive is applied again to the other side of the sound insulation layer. Then, it is hot-pressed at 135°C and 3.5 MPa for 4 minutes.

[0043] Production and Inspection: After computer cutting, double-needle binding is applied to the edges, and lead thread is sewn into the sides and bottom. A hook bag is made at the top.

[0044] Example 2: Reinforced Soundproof Jacquard Curtains

[0045] Fabric layer: High-count, high-density blended (cotton / polyester) fabric is used, and the pre-shrinking conditions are strengthened to 100℃ for 20 minutes.

[0046] Sound insulation layer:

[0047] The fiber ratio of each layer is similar to that in Embodiment 1, but the areal density of the sound insulation layer is increased to 450 g / m². 2 Meanwhile, the proportion of nano-silica aerogel in the middle layer is increased to 25%, while the thickness ratio of the three layers remains unchanged.

[0048] Jacquard surface layer: uses thicker yarns and greater warp and weft density to weave thicker, more three-dimensional jacquard patterns.

[0049] Composite processing: The hot pressing pressure is increased to 4.5MPa to ensure a strong composite of thick materials.

[0050] Manufacturing and testing: A three-line edge binding process is used to increase the strength.

[0051] Example 3: Luxury Soundproof Jacquard Curtains

[0052] step:

[0053] Fabric layer: Made of 80-count combed cotton for a delicate feel.

[0054] Sound insulation layer: surface density reduced to 220g / m² 2 The proportion of nano-aerogel in the middle layer is reduced to 10% to control cost and weight, and the fibers in each layer are finer to maintain the integrity of the gradient structure.

Claims

1. A method for manufacturing soundproof jacquard curtains, characterized in that: Includes the following steps: Step 1: Fabric layer preparation. One of the following fabrics is used: high-count, high-density pure cotton or blended fabric. After desizing, boiling, and bleaching, it undergoes pre-shrinking treatment to obtain the base fabric layer. Step 2: Sound insulation layer preparation. Gradient density composite fiber felt is used, which consists of three fiber layers from bottom to top to obtain the sound insulation layer. Step 3: Jacquard surface preparation. Warp yarn: bicomponent composite yarn; weft yarn: heterogeneous shrinkage blended yarn. Using an electronic jacquard machine, a raised and recessed jacquard pattern is designed. The three-dimensional effect of the pattern is enhanced by the difference in float length between the warp and weft yarns, thus obtaining the jacquard surface. Step 4, multi-layer composite processing: spray water-based environmentally friendly adhesive evenly on the back of the base fabric layer, and stack the sound insulation layer and the glued base fabric layer together. At the same time, apply adhesive to the other side of the sound insulation layer as well, and then perform hot pressing composite through a flatbed hot press to obtain the curtain fabric. Step 5: Production and Inspection. According to the size specifications of the curtains, use a computer-controlled automatic cutting machine to cut them. Use double-needle or triple-thread binding to sew the edges together. Make a hook bag at the top of the curtains and sew lead thread into the side and bottom edges. Install curtain hooks and Velcro. At the same time, conduct sound insulation tests, appearance inspections, size measurements, and peel strength tests to obtain the soundproof jacquard curtains.

2. The method for manufacturing a soundproof jacquard curtain according to claim 1, characterized in that: The pre-shrinkage treatment is performed using a mechanical pre-shrinking machine at a temperature of 80-100℃ for 10-20 minutes.

3. The method for manufacturing a soundproof jacquard curtain according to claim 1, characterized in that: The fiber layer comprises, from bottom to top, an upper layer, a middle layer, and a lower layer; The upper layer is a fiber web formed by mixing and combing low-melting-point polyester fibers and hollow glass microspheres; The middle layer is a blend of conventional polyester fibers and nano-silica aerogel, combed into a middle layer fiber web; The lower layer is a blend of highly crimped viscose fibers and short flax fibers, combed into a lower fiber web; The three-layer fiber web is bonded together by hot air to form a gradient density structure.

4. The method for manufacturing a soundproof jacquard curtain according to claim 1, characterized in that: The areal density of the gradient density composite fiber felt is 200-500 g / m³. 2 The thickness ratio of the three-layer fiber web is upper layer: middle layer: lower layer = 1:1.5:

1.

5. A method for manufacturing a soundproof jacquard curtain according to claim 3, characterized in that: The upper fiber web contains low-melting-point polyester fibers with a melting point of 120-140℃ and hollow glass microspheres with a particle size of 10-50μm; the middle fiber web contains nano-silica aerogel particles with a particle size of 20-100nm; and the lower fiber web contains flax staple fibers with a length of 10-30mm.

6. The method for manufacturing a soundproof jacquard curtain according to claim 1, characterized in that: The bicomponent composite yarn is a PET / PTT parallel composite fiber, and the heteroshrunk blended yarn is a blend of cationic dyeable polyester and ordinary polyester, with a blending ratio of 1:1.

5.

7. A method for manufacturing a soundproof jacquard curtain according to claim 1, characterized in that: The water-based environmentally friendly adhesive is an acrylic adhesive with a viscosity of 1000-3000 mPa·s. During hot pressing, the temperature of the flatbed hot press is controlled at 120-150℃, the pressure is 2-5 MPa, and the hot pressing time is 3-5 minutes.