A method for manufacturing a moisture-proof and anti-caking cotton quilt

Abstract

The application discloses a kind of production methods of damp-proof and anti-caking cotton quilt and cotton quilt made by the method, belong to the technical field of home textile processing.The production method sequentially includes preparation of auxiliary agent, vacuum negative pressure soaking, low-temperature ventilation drying and setting, multi-pass opening, three-dimensional quilting and sewing assembly setting step, by three-proofing agent form nanoscale hydrophobic layer on the surface of Xinjiang cotton fiber, combined with gradient opening and three-dimensional quilting process, realize the synergistic effect of chemical modification and physical anti-caking.The process parameters of the application are controllable, the equipment used is conventional equipment in the home textile industry, suitable for large-scale production;The cotton quilt prepared has the properties of damp-proof, anti-caking, waterproof, stain-proof and oil-proof, and retains the natural properties of Xinjiang cotton, such as warmth, skin-friendly and air permeability.The structure is stable, and the use durability is strong.Compared with the traditional unmodified cotton quilt, it has obvious advantages and good market application value.

Description

Technical Field

[0001] This invention relates to the field of home textile processing technology, and in particular to a method for manufacturing a moisture-proof and anti-caking cotton quilt. Background Technology

[0002] Cotton quilts, as traditional bedding, have always been a preferred home textile product for consumers due to the excellent warmth, skin-friendliness, and breathability of natural Xinjiang cotton fibers. However, the molecular structure of natural cotton fibers contains a large number of hydrophilic hydroxyl groups, which gives them inherent defects and exposes many problems during daily use: On the one hand, cotton fibers easily absorb moisture from the environment. After absorbing moisture, the hydrogen bonding force between fibers increases significantly, causing the cotton fibers to stick together and clump together. After long-term compression, use, and changes in temperature and humidity, the cotton layer gradually hardens and shrinks in thickness, forming a serious "caking" phenomenon. The fluffiness of the quilt decreases significantly, and the warmth retention also declines sharply. On the other hand, the surface of hydrophilic cotton fibers easily absorbs impurities such as oil and dust from daily life. Not only is it difficult to clean, but it is also prone to the growth of mold and bacteria, producing unpleasant odors and affecting hygiene. At the same time, it will further accelerate the aging and compaction of the cotton core, shortening the lifespan of the cotton quilt.

[0003] To address these issues, existing technologies attempt to waterproof and moisture-proof textiles. However, most of these technologies focus on finishing the outer fabric, such as coatings and laminations. While these methods can achieve waterproofing to some extent, they severely sacrifice the textile's breathability, making them unsuitable for cotton quilt fillings that require continuous breathability and warmth. A few technologies attempt simple impregnation modification of cotton fibers, but these often use atmospheric pressure impregnation, resulting in uneven penetration of the waterproofing agents, which only adhere to the fiber surface. The modified layer has weak bonding with the fibers, leading to poor durability. Furthermore, the drying process after modification easily causes fiber bundles to stick together, and the lack of subsequent targeted opening processes can damage the natural three-dimensional crimp structure of cotton fibers. This makes it difficult to balance the modification effect with the fluffy and warm properties of cotton quilts, failing to fundamentally solve the core problem of moisture absorption and compaction in cotton quilts.

[0004] Based on this, the development of a cotton quilt manufacturing method that can achieve deep and uniform hydrophobic modification of Xinjiang cotton fibers, while preserving and locking in the natural fluffy structure of cotton fibers to the greatest extent after modification, so that it has both long-lasting moisture-proof, anti-caking, waterproof, stain-proof and oil-proof properties, and maintains the inherent advantages of Xinjiang cotton in terms of warmth, skin-friendliness and breathability, has become an urgent technical need to be solved in this field. At the same time, it is also of great significance to improving the quality of cotton quilt products and promoting the technological upgrading of the home textile industry. Summary of the Invention

[0005] The technical problem to be solved by this invention is to address the issues of traditional cotton quilts being prone to moisture absorption, clumping, and lacking waterproof and oil resistance. A method for producing a moisture-proof and anti-caking cotton quilt is provided, which produces a quilt that is waterproof, stain-proof, oil-proof, anti-caking, and moisture-proof, while retaining the natural warmth and softness of Xinjiang cotton. Furthermore, this method is simple and suitable for large-scale production.

[0006] The technical solution adopted by this invention to solve its technical problem is: a method for making a moisture-proof and anti-caking cotton quilt, comprising the following steps: a. Preparation of additives: Mix the three-proof additives with water and stir in a stirring device to prepare a uniform and stable impregnation solution; the three-proof additives are fluoropolymer hydrophobic agents or organosilicon hydrophobic agents. These additives can form a stable bond with the surface of cotton fibers, and the protective film formed after curing has low surface energy and hydrophobic and oleophobic properties. b. Vacuum negative pressure soaking: After removing impurities and short fibers from Xinjiang cotton fibers, they are completely immersed in the impregnation solution and soaked under vacuum negative pressure. After the vacuum is released, soaking continues under normal pressure. The vacuum negative pressure soaking process allows the impregnation solution to fully penetrate into the internal gaps of the Xinjiang cotton fiber bundles and the surface of individual cotton fibers under negative pressure, ensuring that the cotton fibers achieve comprehensive and deep uniform modification and avoiding the problem of uneven modification with "concentrated on the outside and light on the inside". c. Low-temperature ventilation drying and shaping: After soaking, the cotton fibers are drained of surface liquid and placed in a low-temperature ventilation environment for drying. This allows the three-proof additives to cross-link and solidify on the surface of the cotton fibers to form a nano-scale hydrophobic layer. This hydrophobic layer is dense and uniform, does not damage the natural molecular structure of the cotton fibers, and is tightly bound to the cotton fibers, exhibiting strong stability. d. Multi-pass opening: The dried and shaped cotton fibers are passed through a multi-pass opening machine for light opening treatment to restore the natural three-dimensional crimp structure of the cotton fibers and form fluffy wadding. Through multiple light opening treatments, the mechanical force of the opening machine is gradually reduced, the temporary adhesion formed by the cotton fibers during the drying process is gently released, the natural three-dimensional crimp structure of Xinjiang cotton fibers is accurately restored, and fluffy and uniform cotton wadding is formed, ensuring that there is a sufficient layer of still air inside the cotton wadding. e. Three-dimensional quilting assembly and shaping: The fluffy wadding is evenly filled into the duvet cover as a cotton core, and the duvet cover and cotton core are fixed together by three-dimensional quilting process to form an independent three-dimensional air storage cavity; the duvet cover is made of high-count and high-density pure cotton fabric or functional fabric, which has both skin-friendly and protective properties, and works synergistically with the modified cotton core.

[0007] Furthermore, in step a, the mass ratio of the three-proof additive to water is 1:8 to 1:10, and the mixture is stirred at a speed of 200 to 300 r / min for 20 to 40 minutes at room temperature to ensure that the three-proof additive is fully dissolved and the impregnation solution system is uniform and stable.

[0008] Furthermore, in step b, the vacuum degree of the vacuum negative pressure soaking is controlled at -0.07 to -0.09 MPa, the vacuum soaking time is 20 to 40 minutes, and the normal pressure soaking time is 10 to 15 minutes, which further enhances the bonding effect between the auxiliaries and cotton fibers.

[0009] Furthermore, in step c, the temperature of the low-temperature drying is controlled at 70-90°C, the drying time is 1.5-2.5 hours, continuous ventilation is maintained during the drying process to prevent the cotton fibers from degenerating due to high temperature, and at the same time to ensure that the hydrophobic layer is uniformly cured with a thickness controlled at 50-100 nm.

[0010] Furthermore, in step d, the multiple light openings are processed sequentially using 3 to 5 opening machines. The speed of the first opening machine is 800 to 1000 r / min, and the speed of each subsequent opening decreases by 100 to 200 r / min. The speed of the last opening is 300 to 400 r / min, so as to effectively restore the fluffiness without damaging the cotton fibers.

[0011] Furthermore, in step e, the quilting grid size of the three-dimensional quilting process is 8-12cm × 8-12cm, the stitch density is 12-15 stitches / 3cm, and the height of the three-dimensional air storage cavity is 2-3cm, which can effectively limit the displacement and aggregation of the cotton core during use and further prevent caking.

[0012] This invention also protects a moisture-proof and anti-caking cotton quilt made by the above-mentioned method for making moisture-proof and anti-caking cotton quilts. The cotton quilt includes a quilt cover and a cotton core filled inside the quilt cover. The cotton core is made of Xinjiang cotton fibers that have been hydrophobically modified by the above-mentioned process. A nano-scale hydrophobic layer with a thickness of 50-100nm is formed on the surface of the fibers. The cotton core is distributed in a three-dimensional fluffy shape inside the quilt cover and is divided into multiple independent three-dimensional air storage cavities with a height of 2-3cm by a three-dimensional quilting process. Sufficient static air layers are left between the fibers and inside the air storage cavities, which has long-lasting moisture-proof, anti-caking, waterproof, stain-proof and oil-proof properties.

[0013] Compared with the prior art, the present invention has the following significant advantages: 1. Excellent anti-caking performance: Through soaking and modification with three-proof additives, a nano-level hydrophobic layer is formed on the surface of cotton fibers, which effectively blocks water molecules from entering the fiber interior, avoiding hydrogen bonding and caking caused by moisture absorption, and maintaining a soft feel even after long-term use.

[0014] 2. Three-proof function: The modified cotton fiber surface forms a low surface energy protective film, which has the functions of waterproof, oil-proof and stain-proof. Liquid water or oil stains will not penetrate the quilt, making it easy to clean and maintain, thus improving the hygienic performance and service life of the quilt.

[0015] 3. Preserves natural warmth: The nano-level hydrophobic layer does not affect the original porous structure of the cotton fibers. The cotton core is distributed in a three-dimensional, fluffy shape, and a large amount of still air can be effectively stored between the fibers, ensuring the original excellent warmth retention performance of Xinjiang cotton, while the breathability is not affected.

[0016] 4. Simple and easy to scale up: The cotton fiber is modified as a whole by soaking, combined with vacuum negative pressure, low temperature drying, multi-pass opening and three-dimensional quilting. The process is simple, the operation is controllable, the modification effect is uniform and long-lasting, no special complicated equipment is required, and it is suitable for industrial-scale production.

[0017] 5. Stable product structure: The independent three-dimensional air storage cavity formed by the three-dimensional quilting can effectively prevent the cotton core from shifting and local caking, further improving the durability of the cotton quilt. Detailed Implementation

[0018] The present invention will be further illustrated below with reference to specific embodiments. These embodiments are only some, not all, of the embodiments described herein.

[0019] Example 1: A method for making a moisture-proof and anti-caking cotton quilt includes the following steps: 1. Preparation of additives: Select organosilicon hydrophobic agents as three-proof additives. Mix organosilicon hydrophobic agents with deionized water at a mass ratio of 1:9, place in a mixing tank, stir at a speed of 250 r / min for 30 min, and prepare a uniform and stable impregnation solution at room temperature.

[0020] 2. Vacuum negative pressure soaking: After removing impurities and short fibers from the selected Xinjiang long-staple cotton fibers using a cleaning machine, the fibers are completely immersed in the above-mentioned impregnation solution. The impregnation system is evacuated to -0.08MPa and kept at this vacuum level for 30 minutes. After the vacuum is released, the fibers are soaked for another 12 minutes under normal pressure to ensure that the impregnation solution fully penetrates into the cotton fiber bundles.

[0021] 3. Low-temperature ventilation drying and shaping: After soaking, the cotton fibers are taken out of the impregnation solution, drained of surface liquid, and placed in a ventilation drying oven. They are dried at 80°C for 2 hours. During the drying process, continuous ventilation is maintained so that the organosilicon hydrophobic agent cross-links and solidifies on the surface of the cotton fibers, forming a nanoscale hydrophobic layer with a thickness of about 80nm.

[0022] 4. Multi-pass opening: The dried and shaped cotton fibers are passed through four opening machines for light opening treatment. The drum speeds of the opening machines are 900 r / min, 700 r / min, 500 r / min and 350 r / min respectively. This gently removes the fiber adhesion, restores the natural three-dimensional crimp structure of the cotton fibers, and forms fluffy and uniform cotton floss.

[0023] 5. Three-dimensional quilting assembly and shaping: The above-mentioned cotton wadding is evenly filled into the duvet cover made of 40-count high-density pure cotton fabric, ensuring that the cotton core is distributed in a three-dimensional, fluffy shape; then, a three-dimensional quilting process is used for sewing, with the quilting square size being 10cm×10cm and the stitch density being 14 stitches / 3cm, forming an independent three-dimensional air storage cavity with a height of about 2.5cm inside the duvet cover, completing the production of the moisture-proof and anti-caking cotton duvet.

[0024] Example 2: A method for making a moisture-proof and anti-caking cotton quilt includes the following steps: 1. Preparation of additives: Select fluoropolymer hydrophobic agents as three-proof additives. Mix the fluoropolymer hydrophobic agents with deionized water at a mass ratio of 1:10, place the mixture in a mixing tank, and stir at a speed of 200 r / min for 40 min. Prepare a uniform and stable impregnation solution at room temperature.

[0025] 2. Vacuum negative pressure soaking: After removing impurities and short fibers from the selected Xinjiang cotton fibers using a cotton cleaning machine, the fibers are completely immersed in the above-mentioned impregnation solution. The impregnation system is evacuated to -0.07MPa and kept at this vacuum level for 40 minutes. After the vacuum is released, the fibers are soaked for another 15 minutes under normal pressure to ensure that the impregnation solution fully penetrates into the cotton fiber bundles.

[0026] 3. Low-temperature ventilation drying and shaping: After soaking, the cotton fibers are taken out of the impregnation solution, drained of surface liquid, and placed in a ventilation drying oven. They are dried at 70°C for 2.5 hours. During the drying process, continuous ventilation is maintained to allow the fluoropolymer hydrophobic agent to cross-link and solidify on the surface of the cotton fibers, forming a nanoscale hydrophobic layer with a thickness of about 50nm.

[0027] 4. Multi-pass opening: The dried and shaped cotton fibers are passed through three opening machines in sequence for light opening treatment. The drum speeds of the opening machines are 800r / min, 600r / min and 400r / min in sequence. This gently removes the fiber adhesion, restores the natural three-dimensional crimp structure of the cotton fibers, and forms fluffy and uniform cotton floss.

[0028] 5. Three-dimensional quilting assembly and shaping: The above-mentioned cotton wadding is evenly filled into the duvet cover made of breathable functional polyester fabric, ensuring that the cotton core is distributed in a three-dimensional fluffy shape; then, a three-dimensional quilting process is used for sewing, with the quilting square size being 8cm×8cm and the stitch density being 12 stitches / 3cm, forming an independent three-dimensional air storage cavity with a height of about 2cm inside the duvet cover, thus completing the production of the moisture-proof and anti-caking cotton duvet.

[0029] Example 3 A method for making a moisture-proof and anti-caking cotton quilt includes the following steps: 1. Preparation of additives: Select organosilicon hydrophobic agents as three-proof additives. Mix organosilicon hydrophobic agents with deionized water at a mass ratio of 1:8, place in a mixing tank, stir at 300 r / min for 20 min, and prepare a uniform and stable impregnation solution at room temperature.

[0030] 2. Vacuum negative pressure soaking: After removing impurities and short fibers from the selected Xinjiang long-staple cotton fibers using a cleaning machine, the fibers are completely immersed in the above-mentioned impregnation solution. The impregnation system is evacuated to -0.09MPa and kept at this vacuum level for 20 minutes. After the vacuum is released, the fibers are soaked for another 10 minutes under normal pressure to ensure that the impregnation solution fully penetrates into the cotton fiber bundles.

[0031] 3. Low-temperature ventilation drying and shaping: After soaking, the cotton fibers are taken out of the impregnation solution, drained of surface liquid, and placed in a ventilation drying oven. They are dried at 90℃ for 1.5 hours. During the drying process, continuous ventilation is maintained so that the organosilicon hydrophobic agent cross-links and solidifies on the surface of the cotton fibers, forming a nanoscale hydrophobic layer with a thickness of about 100nm.

[0032] 4. Multi-pass opening: The dried and shaped cotton fibers are passed through 5 opening machines for light opening treatment. The drum speeds of the opening machines are 1000r / min, 800r / min, 600r / min, 400r / min and 300r / min respectively. This gently removes the fiber adhesion, restores the natural three-dimensional crimp structure of the cotton fibers, and forms fluffy and uniform cotton floss.

[0033] 5. Three-dimensional quilting assembly and shaping: The above-mentioned cotton wadding is evenly filled into the duvet cover made of 60-count high-density pure cotton fabric, ensuring that the cotton core is distributed in a three-dimensional fluffy shape; then, it is sewn using a three-dimensional quilting process, with the quilting square size being 12cm×12cm and the stitch density being 15 stitches / 3cm, forming an independent three-dimensional air storage cavity with a height of about 3cm inside the duvet cover, thus completing the production of the moisture-proof and anti-caking cotton duvet.

[0034] Performance testing The moisture-proof and anti-caking cotton quilts prepared in Examples 1-3 above were compared with traditional unmodified cotton quilts in terms of performance. The test conditions were based on daily use environment, with some items simulating an extreme humid environment (85% humidity). The test results are shown in Table 1 below: Table 1

[0035] The test results above show that the cotton quilt made by the method of the present invention has excellent waterproof, oil-proof, moisture-proof and anti-caking properties. Moreover, after long-term use, in humid environments and after washing, there is no significant decline in various properties. At the same time, it can maintain good fluffiness and breathability, which is far superior to traditional cotton quilts, fully demonstrating the advanced nature and practicality of the technical solution of the present invention.

[0036] The above embodiments are only used to explain the present invention and are not intended to limit the protection of the present invention. Any non-substantial modifications made based on the essential solution of the present invention should fall within the protection scope of the present invention.

Claims

1. A method for manufacturing a moisture-proof and anti-caking cotton quilt, characterized in that, Includes the following steps: a. Preparation of additives: Mix the three-proof additive with water and stir in a mixing device to prepare a uniform and stable impregnation solution; the three-proof additive is a fluoropolymer hydrophobic agent or an organosilicon hydrophobic agent; b. Vacuum negative pressure soaking: After removing impurities and short fibers from Xinjiang cotton fibers, they are completely immersed in the soaking solution and soaked under vacuum negative pressure. After the vacuum is released, soaking continues under normal pressure. c. Low-temperature ventilation drying and shaping: After soaking, the cotton fibers are drained of surface liquid and placed in a low-temperature ventilation environment to dry, so that the three-proof additives cross-link and solidify on the surface of the cotton fibers to form a nano-scale hydrophobic layer. d. Multi-pass opening: The dried and shaped cotton fibers are passed through a multi-pass opening machine for light opening treatment to restore the natural three-dimensional crimp structure of the cotton fibers and form fluffy wadding; e. Three-dimensional quilting assembly and shaping: The fluffy wadding is evenly filled into the duvet cover as a cotton core, and the duvet cover and cotton core are fixed together by three-dimensional quilting process to form an independent three-dimensional air storage cavity; the duvet cover is made of high-count, high-density pure cotton fabric or functional fabric.

2. The method for manufacturing a moisture-proof and anti-caking cotton quilt according to claim 1, characterized in that, In step a, the mass ratio of the three-proof additive to water is 1:8 to 1:10, and the mixture is stirred at a speed of 200 to 300 r / min for 20 to 40 minutes at room temperature.

3. The method for manufacturing a moisture-proof and anti-caking cotton quilt according to claim 1, characterized in that, In step b, the vacuum degree of the vacuum negative pressure immersion is controlled at -0.07 to -0.09 MPa, the vacuum immersion time is 20 to 40 minutes, and the normal pressure immersion time is 10 to 15 minutes.

4. The method for manufacturing a moisture-proof and anti-caking cotton quilt according to claim 1, characterized in that, In step c, the drying temperature is 70–90°C, the drying time is 1.5–2.5 h, and the thickness of the nanoscale hydrophobic layer is 50–100 nm.

5. The method for manufacturing a moisture-proof and anti-caking cotton quilt according to claim 1, characterized in that, In step d, the loosening machine has 3 to 5 stages, and the drum speed is set to decrease in a gradient. The speed of the first loosening machine is 800 to 1000 r / min, and the speed of each subsequent stage decreases by 100 to 200 r / min. The speed of the last loosening machine is 300 to 400 r / min.

6. The method for manufacturing a moisture-proof and anti-caking cotton quilt according to claim 1, characterized in that, In step e, the grid size of the three-dimensional quilting is 8-12cm × 8-12cm, the stitch density is 12-15 stitches / 3cm, and the height of the formed three-dimensional air storage cavity is 2-3cm.

7. A moisture-proof and anti-caking cotton quilt, characterized in that, The quilt is prepared by the method for making moisture-proof and anti-caking cotton quilt according to any one of claims 1 to 6.

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