Low-temperature easy-to-dye high-water-absorption sable fabric and production method thereof

Abstract

This invention discloses a low-temperature dyeable, highly absorbent chenille fabric and its production method. The fabric includes warp and weft yarns. The warp yarns are low-temperature dyeable cationic polyester yarns, and the weft yarns are cationic dyeable polyester chenille yarns. The fabric has a 1-up-2-down double weft structure, woven from one set of warp yarns interwoven with two sets of weft yarns: the outer weft and the inner weft. Both the outer and inner weft yarns are cationic dyeable polyester chenille yarns. The outer weft yarns interweave with the warp yarns in a 1-up-2-down pattern, while the inner weft yarns interweave with the warp yarns in a 2-up-1-down pattern. Long floats of the cationic dyeable polyester chenille yarns cover the front and back sides of the fabric, forming a double-sided pile layer. This invention achieves a combination of high absorbency, low energy consumption, and long-lasting pile bonding under normal pressure dyeing conditions at 100℃ through the synergistic cooperation of the low-temperature cationic polyester warp yarns and the cationic dyeable polyester chenille weft yarns in a 1-up-2-down double weft structure, overcoming the technical defects of conventional chenille products that require high-temperature and high-pressure dyeing and have insufficient water absorption rates.

Description

Technical Field

[0001] This invention belongs to the field of textile technology, specifically relating to a low-temperature easy-dyeing, highly absorbent chenille fabric and its production method. Background Technology

[0002] Chenille yarn is a fancy yarn made by twisting core yarn with downy fibers. It has a full pile and a soft hand feel, and is widely used in the production of bathroom textiles such as towels, bath towels, and beach towels.

[0003] The existing chenille towel products mainly have the following problems: Firstly, the dyeing process is energy-intensive. Conventional polyester warp yarns require dyeing with disperse dyes under high temperature and high pressure conditions of around 130℃ and 0.2MPa, resulting in significant consumption of steam and electricity. Simultaneously, the high-temperature treatment causes thermal shrinkage and molecular chain relaxation in chenille down yarn fibers, leading to decreased pile elasticity, a stiffer hand feel, and a tendency to pill after prolonged use.

[0004] Secondly, the water absorption rate is limited. Most existing chenille towels use plain or twill weaves. When chenille is interwoven with the warp yarns as weft, the weft segments that sink below the warp yarns are compressed inside the fabric. Their fibers cannot effectively contact the skin surface, thus limiting water absorption efficiency and making it difficult to meet the need for immediate drying. Increasing the weft density or using finishing brushing methods has limited effect and may increase costs or result in unsustainable results. Summary of the Invention

[0005] To address the aforementioned technical problems, the present invention aims to provide a low-temperature dyeable, highly absorbent chenille fabric and its production method. This invention achieves a combination of high absorbency, low energy consumption, and durable pile bonding under normal pressure dyeing conditions at 100℃ through the synergistic cooperation of low-temperature cationic polyester warp yarns and cationic dyeable polyester chenille weft yarns in a 1-up, 2-down weft double weft structure. This overcomes the technical shortcomings of conventional chenille products, which require high-temperature, high-pressure dyeing and have insufficient water absorption rates.

[0006] To achieve the above-mentioned technical objectives and effects, the present invention is implemented through the following technical solution: The present invention provides a low-temperature dyeable, highly absorbent chenille fabric, which includes warp yarns and weft yarns. The warp yarns are low-temperature dyeable cationic polyester yarns, and the weft yarns are cationic dyeable polyester chenille yarns. The fabric is a 1-up 2-down weft double structure, which is woven from one set of warp yarns and two sets of weft yarns: the outer weft and the inner weft. Both the outer and inner weft are cationic dyeable polyester chenille yarns. The outer weft interweaves with the warp yarns in a 1-up-2-down pattern, and the inner weft interweaves with the warp yarns in a 2-up-1-down pattern. The long floats of the cationic dyeable polyester chenille yarns cover the front and back sides of the fabric respectively, forming a double-sided pile layer. The fabric has a warp density of 380-400 threads / 10cm and a weft density of 280-340 threads / 10cm.

[0007] Furthermore, the warp yarn is 75D / 72F DTY low-temperature dyeing cationic polyester yarn, which is a modified copolyester yarn with sulfonic acid groups introduced into the polyester molecular chain, and can be dyed with cationic dyes under normal pressure at 100°C. The weft yarn is 10-count cationic dyeable polyester chenille yarn, and its down yarn is 75D / 144F cationic dyeable polyester filament twisted and brushed yarn with a single filament fineness of 0.5-0.8dtex. The core yarn is 32-count cationic dyeable polyester staple fiber.

[0008] Furthermore, the fabric is dyed with cationic dyes at 100°C and normal pressure, with a dyeing bath ratio of 1:8 to 1:12, a dye bath pH of 4.5 to 5.5, a dyeing heating rate of 0.8°C to 1.5°C / min, and a holding time of 2 to 4 hours.

[0009] Furthermore, in the 1-up-2-down weft double weft structure, the face weft interweaves with the warp yarns in a 1-up-2-down pattern to form a front long floating section, and the back weft interweaves with the warp yarns in a 2-up-1-down pattern to form a back long floating section. The weft insertion order of the face weft and the back weft is 1:1 alternating weft insertion. The cationic dyeable polyester chenille long floating sections on both sides of the fabric form a synergistic water absorption structure.

[0010] Furthermore, the fabric has a water penetration time of ≤2 seconds, a water retention rate of ≥400% per unit area, a tear resistance of ≥380N, and a dimensional change rate of ≤3% after washing.

[0011] Another aspect of the present invention provides a method for producing the aforementioned low-temperature easy-dyeing, highly absorbent chenille fabric, comprising the following steps: (1) Warping process: Low-temperature dyed cationic polyester yarn is warped in batches. The warping tension is controlled at 18-22 cN and the tension fluctuation deviation is controlled within ±2 cN. After the warping is completed, 0.8%-1.2% of low-temperature soluble oil agent is applied to the surface of the warp yarn. (2) Weaving process: Weaving is carried out using an air-jet loom. Four types of weft yarns are introduced into the shed in sequence in a cyclical manner. When the outer weft is inserted, the warp yarns open in a 1-up-2-down pattern. When the inner weft is inserted, the warp yarns open in a 2-up-1-down pattern. The loom speed is controlled at 400-450 r / min. (3) Pretreatment process: The fabric is pretreated and pre-shrinked at 80-90℃ and then washed with tension-free flat-width water. (4) Low temperature dyeing process: Disperse dyes are used for dyeing at 100℃ and normal pressure. The temperature is increased at a rate of 0.8℃~1.5℃ / min. Acetic acid is added as a retarding agent. The temperature is maintained for 2~4 hours, and the pH value of the dye bath is controlled at 4.5~5.5. (5) Finishing process: After dyeing, the fabric is dried and shaped by hot air at 150℃~160℃, then brushed, and finally impregnated with softener.

[0012] Furthermore, the air-jet loom described in step (2) is equipped with at least four nozzles, in which the four nozzles participate in weft insertion in sequence in a cyclical manner; the 1-up-2-down regular opening is: when inserting the outer weft, the warp yarns form a shed according to the rule that one of every three yarns is on top and two are on the bottom; the 2-up-1-down regular opening is: when inserting the inner weft, the warp yarns form a reverse shed according to the rule that two of every three yarns are on top and one is on the bottom.

[0013] Furthermore, the specific process parameters for low-temperature dyeing in step (4) are as follows: dye bath ratio 1:8 to 1:12, acetic acid dosage 0.5 to 1.5 g / L, dyeing and heat preservation time 3 hours, and after dyeing, cooling to below 60°C at a rate of 1.0 to 2.0°C / min and draining the solution.

[0014] Furthermore, in step (5), the hot air drying and setting adopts low tension feeding, and the width of the setting machine is set to 1.05 to 1.10 times the width of the finished product; the brushing treatment adopts brushing roller to brush the front of the fabric in the opposite direction, and combs the fallen cationic dyeable polyester chenille fibers upright; the softener is a weak cationic silicone softener, and the padding residue rate is 65% to 75%.

[0015] The present invention also provides an application of the aforementioned low-temperature dyeable, highly absorbent chenille fabric in the preparation of towels, bath towels, or beach towels.

[0016] The beneficial effects of this invention are as follows: (1) The warp yarn in this invention is low-temperature dyeable cationic polyester, and the weft yarn is cationic dyeable polyester chenille. Both are modified fiber systems that can be dyed with cationic dyes and can be dyed together in a normal pressure bath at 100℃. Unlike conventional polyester, which requires high temperature and high pressure dyeing at 130℃, causing irreversible damage to the internal structure of the fiber, the low-temperature dyeing conditions of this invention preserve the crimp elasticity and fluffy shape of the downy yarn in the cationic dyeable polyester chenille weft yarn. No high temperature and high pressure equipment is required throughout the dyeing process, the steam consumption is lower than that of conventional polyester dyeing process, the residual liquor after dyeing is clear and can be recycled, saving dyeing water; the dyeing time of cationic dyeable polyester is short, the dyeing rate is high, the dye utilization rate is high, and the color fastness is better than that of conventional polyester.

[0017] (2) In this invention, both the outer and inner weft threads are cationic dyeable polyester chenille. The 1-up, 2-down double weft structure creates long chenille floats on both sides. Each chenille weft yarn is exposed on its own side, and the long floats on both sides do not overlap, maximizing the capillary water absorption of the pile on both sides simultaneously. This avoids the structural defect in conventional single-layer structures where some weft yarns are covered by warp yarns and cannot come into contact with water. The fluffy chenille pile on the surface, through the double weft double-sided water-conducting structure, significantly shortens the drip penetration time and significantly improves the water retention rate per unit area, allowing for rapid absorption of moisture from the skin surface and meeting the immediate drying needs in bathing scenarios.

[0018] (3) The 1-up, 2-down weft double weft structure in this invention allows the long floats of chenille yarn to cover the fabric surface to ensure the exposed area of ​​the pile, while each chenille weft yarn is fixed in the fabric by the warp yarns at dispersed interlacing points. This structure achieves a balance between ensuring sufficient pile exposure (to perform water absorption) and strong bonding (to resist shedding during washing), overcoming the technical contradiction in conventional chenille fabrics where it is difficult to balance the degree of pile exposure and the strength of bonding. After multiple washing tests, the fabric has a low shedding rate, stable dimensions, good resilience, and practical properties of being machine washable and wrinkle-free.

[0019] (4) The present invention uses a warp density of 380-400 threads / 10cm and a weft density of 280-340 threads / 10cm. The double weft structure uses two sets of chenille weft yarns on the front and back. The number of chenille piles per unit area is sufficient, and the long floats cover the bottom without exposing the bottom. The two sets of weft yarns form a double-layer pile distribution in the thickness direction. The pile layer is thick and full. Combined with the interlacing strength of the high-density double weft structure, the tear resistance of the fabric reaches more than 380N. It can still maintain a full pile state after long-term use. Detailed Implementation

[0020] 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.

[0021] This invention provides a low-temperature dyeable, highly absorbent chenille fabric, comprising warp and weft yarns. The warp yarns are made of low-temperature dyeing cationic polyester yarn, and the weft yarns are made of cationic dyeable polyester chenille yarn.

[0022] For example, the warp yarn is selected from 75D / 72F DTY low-temperature dyeing cationic polyester yarn. This yarn is a modified copolyester yarn with sulfonic acid groups introduced into the polyester molecular chain, and can be dyed with cationic dyes under normal pressure at 100℃. The weft yarn is selected from 10-count cationic dyeable polyester chenille yarn, and its down yarn is made of 75D / 144F cationic dyeable polyester filament twisted and brushed yarn with a single filament fineness of 0.5-0.8 dtex. The core yarn is made of 32-count cationic dyeable polyester staple fiber.

[0023] The fabric has a 1-up, 2-down weft double weft structure, woven from one set of warp yarns and two sets of weft yarns: the outer weft and the inner weft. Both the outer and inner wefts are cationic dyeable polyester chenille yarns. The outer weft interweaves with the warp yarns in a 1-up, 2-down pattern, while the inner weft interweaves with the warp yarns in a 2-up, 1-down pattern. In this weft configuration, the long floats of the cationic dyeable polyester chenille yarn cover both the front and back sides of the fabric, forming a double-sided pile layer.

[0024] Specifically, the face weft interweaves with the warp yarns in a 1-up-2-down pattern to form the front long float, while the back weft interweaves with the warp yarns in a 2-up-1-down pattern to form the back long float. The face and back wefts are alternately inserted in a 1:1 ratio. The cationic dyeable polyester chenille long floats on both sides of the fabric together constitute the water-absorbing structure.

[0025] The warp density of the fabric is 380-400 threads / 10cm, and the weft density is 280-340 threads / 10cm.

[0026] The fabric has a water penetration time of ≤2 seconds, a water retention rate of ≥400% per unit area, a tear strength of ≥380N, and a dimensional change rate of ≤3% after washing.

[0027] The present invention also provides a method for producing the above-mentioned fabric, comprising the following steps.

[0028] (1) Warping process The low-temperature dyed cationic polyester warp yarns are warped in batches. The warping tension is controlled at 18–22 cN, and the tension fluctuation deviation is controlled within ±2 cN. After warping, 0.8%–1.2% of a low-temperature easily soluble oil agent is applied to the surface of the warp yarns.

[0029] (2) Weaving process The weaving is performed using an air-jet loom. For example, the air-jet loom may be equipped with at least four nozzles, which sequentially and cyclically participate in weft insertion, introducing four types of weft yarns in a group into the shed sequentially and cyclically. When inserting the face weft, the warp yarns open in a 1-up-2-down pattern, that is, the shed is formed with one out of every three warp yarns on top and two on the bottom; when inserting the back weft, the warp yarns open in a 2-up-1-down pattern, that is, the reverse shed is formed with two out of every three warp yarns on top and one on the bottom. The loom speed is controlled at 400–450 r / min.

[0030] (3) Pre-treatment process The fabric is pretreated and pre-shrinked at 80-90℃, and then washed in a tension-free, flat-width manner.

[0031] (4) Low-temperature dyeing process Disperse dyes were used for dyeing at 100℃ and normal pressure. The temperature was increased at a rate of 0.8℃~1.5℃ / min, acetic acid was added as a retarding agent, and the temperature was maintained for 2~4 hours, while controlling the pH value of the dye bath at 4.5~5.5.

[0032] Preferably, the dye bath ratio is 1:8 to 1:12, the amount of acetic acid is 0.5 to 1.5 g / L, the dyeing and heat preservation time is 3 hours, and after dyeing, the temperature is lowered to below 60°C at a rate of 1.0 to 2.0°C / min and the solution is drained.

[0033] (5) Post-processing The dyed fabric is dried and set with hot air at 150℃~160℃. Low-tension feeding is used during setting, and the setting machine width is set to 1.05~1.10 times the finished product width. After setting, a brushing treatment is performed, using a brushing roller to brush the fabric face in the opposite direction, straightening the flattened cationic dyeable polyester chenille fibers. Finally, a softener is applied. Preferably, the softener is a weak cationic silicone softener, with a padding rate of 65%~75%.

[0034] The fabric described above can be used to prepare bathroom textiles such as towels, bath towels, or beach towels.

[0035] The present invention will be further described below through specific embodiments.

[0036] Example This embodiment provides a low-temperature dyeable, highly absorbent chenille fabric, the preparation steps of which are as follows.

[0037] Warping process: The 75D / 72F DTY low-temperature dyed cationic polyester yarn is warped in batches. The warping tension is controlled at 20cN and the tension fluctuation deviation is controlled within ±2cN. After the warping is completed, 1.0% of low-temperature soluble oil agent is applied to the surface of the warp yarn.

[0038] Weaving Process: An air-jet loom with four nozzles is used. The weft insertion sequence is set in a cyclical manner: nozzle 1, nozzle 2, nozzle 3, and nozzle 4. Four types of weft yarns are introduced into the shed in a cyclical manner, grouped together. When inserting the outer weft, the warp yarns open in a 1-up, 2-down pattern, meaning that for every three warp yarns, one is on top and two are on the bottom, forming the shed. When inserting the inner weft, the warp yarns open in a 2-up, 1-down pattern, meaning that for every three warp yarns, two are on top and one is on the bottom, forming the reverse shed. The loom speed is controlled at 420 r / min. The warp density is set to 390 ends / 10cm, and the weft density is set to 310 ends / 10cm.

[0039] Pretreatment process: The fabric is pretreated at 85℃ and pre-shrinked by tension-free flat-width washing.

[0040] Dyeing process: Disperse dyes are used at 100℃ and normal pressure, with a liquor ratio of 1:10. The temperature is increased to 100℃ at a rate of 1.0℃ / min, and 1.0g / L acetic acid is added as a retarding agent. The mixture is kept at this temperature for 3 hours, and the pH of the dye bath is controlled at 5.0. After dyeing, the temperature is lowered to below 60℃ at a rate of 1.5℃ / min before draining the solution.

[0041] Post-finishing process: After dyeing, the fabric is dried and set with hot air at 155℃, fed in with low tension, and the width of the setting machine is set to 1.08 times the finished product width. After setting, the fabric is brushed in the reverse direction on the front side with a brushing roller to straighten the flattened chenille fibers. Finally, a weak cationic silicone softener is applied, with a pick-up rate of 70%.

[0042] According to the test, the water penetration time of the fabric obtained in this embodiment is 1.2 seconds, the water retention rate per unit area is 420%, the tear strength is 395N, and the dimensional change rate after washing is 2.1%.

[0043] 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.

[0044] 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 low-temperature dyeable, highly absorbent chenille fabric, characterized in that, It includes warp yarns and weft yarns, wherein the warp yarns are low-temperature dyed cationic polyester yarns and the weft yarns are cationic dyeable polyester chenille yarns; the fabric is a 1-up 2-down weft double structure, which is woven from one set of warp yarns and two sets of weft yarns, the outer weft and the inner weft; Both the outer and inner weft are cationic dyeable polyester chenille yarns. The outer weft interweaves with the warp yarns in a 1-up-2-down pattern, and the inner weft interweaves with the warp yarns in a 2-up-1-down pattern. The long floats of the cationic dyeable polyester chenille yarns cover the front and back sides of the fabric respectively, forming a double-sided pile layer. The fabric has a warp density of 380-400 threads / 10cm and a weft density of 280-340 threads / 10cm.

2. The low-temperature dyeable, highly absorbent chenille fabric according to claim 1, characterized in that, The warp yarn is 75D / 72F DTY low-temperature dyeing cationic polyester yarn. This yarn is a modified copolyester yarn with sulfonic acid groups introduced into the polyester molecular chain, and can be dyed with cationic dyes under normal pressure at 100℃. The weft yarn is 10-count cationic dyeable polyester chenille yarn, and its down yarn is 75D / 144F cationic dyeable polyester filament twisted and brushed yarn with a single filament fineness of 0.5-0.8dtex. The core yarn is 32-count cationic dyeable polyester staple fiber.

3. The low-temperature easily dyed, highly absorbent chenille fabric according to claim 1, characterized in that, The fabric is dyed with cationic dyes at 100℃ and normal pressure, with a dyeing bath ratio of 1:8 to 1:12, a dye bath pH of 4.5 to 5.5, a dyeing heating rate of 0.8℃ to 1.5℃ / min, and a holding time of 2 to 4 hours.

4. The low-temperature easily dyed, highly absorbent chenille fabric according to claim 1, characterized in that, In the 1-up-2-down double weft structure, the face weft interweaves with the warp yarns in a 1-up-2-down pattern to form a front long floating section, and the back weft interweaves with the warp yarns in a 2-up-1-down pattern to form a back long floating section. The weft insertion order of the face weft and the back weft is 1:1 alternating weft insertion. The cationic dyeable polyester chenille long floating sections on both sides of the fabric form a synergistic water absorption structure.

5. The low-temperature easily dyeable, highly absorbent chenille fabric according to claim 1, characterized in that, The fabric has a water penetration time of ≤2 seconds, a water retention rate of ≥400% per unit area, a tear resistance of ≥380N, and a dimensional change rate of ≤3% after washing.

6. A method for producing low-temperature dyeable, highly absorbent chenille fabric as described in any one of claims 1 to 5, characterized in that, Includes the following steps: (1) Warping process: Low-temperature dyed cationic polyester yarn is warped in batches. The warping tension is controlled at 18-22 cN and the tension fluctuation deviation is controlled within ±2 cN. After the warping is completed, 0.8%-1.2% of low-temperature soluble oil agent is applied to the surface of the warp yarn. (2) Weaving process: Weaving is carried out using an air-jet loom. Four types of weft yarns are introduced into the shed in sequence in a cyclical manner. When the outer weft is inserted, the warp yarns open in a 1-up-2-down pattern. When the inner weft is inserted, the warp yarns open in a 2-up-1-down pattern. The loom speed is controlled at 400-450 r / min. (3) Pretreatment process: The fabric is pretreated and pre-shrinked at 80-90℃ and then washed with tension-free flat-width water. (4) Low temperature dyeing process: Disperse dyes are used for dyeing at 100℃ and normal pressure. The temperature is increased at a rate of 0.8℃~1.5℃ / min. Acetic acid is added as a retarding agent. The temperature is maintained for 2~4 hours, and the pH value of the dye bath is controlled at 4.5~5.

5. (5) Finishing process: After dyeing, the fabric is dried and shaped by hot air at 150℃~160℃, then brushed, and finally impregnated with softener.

7. The production method according to claim 6, characterized in that, The air-jet loom described in step (2) is equipped with at least four nozzles, in which the four nozzles participate in weft insertion in sequence in a cyclical manner; the 1-up-2-down regular opening is: when inserting the outer weft, the warp yarns form a shed according to the rule that one of every three yarns is on top and two are on the bottom; the 2-up-1-down regular opening is: when inserting the inner weft, the warp yarns form a reverse shed according to the rule that two of every three yarns are on top and one is on the bottom.

8. The production method according to claim 6, characterized in that, The specific process parameters for low-temperature dyeing in step (4) are as follows: dye bath ratio 1:8 to 1:12, acetic acid dosage 0.5 to 1.5 g / L, dyeing and heat preservation time 3 hours, and after dyeing, cooling to below 60℃ at a rate of 1.0 to 2.0℃ / min and draining the solution.

9. The production method according to claim 6, characterized in that, In step (5), the hot air drying and setting adopts low tension feeding, and the width of the setting machine is set to 1.05 to 1.10 times the width of the finished product; the brushing treatment adopts brushing roller to brush the front of the fabric in the opposite direction, and combs the fallen cationic dyeable polyester chenille fibers upright; the softener is a weak cationic silicone softener with a padding residue rate of 65% to 75%.

10. The use of the low-temperature dyeable, highly absorbent chenille fabric according to any one of claims 1 to 5 in the preparation of towels, bath towels or beach towels.