Research And Development Of Down Quilt Fabric Of Integral Weaving And Forming

Down quilt is an excellently warm bedding which is also thin,soft,comfortable,and durable,so that its utilization rate is gradually improving at home and abroad.However,the traditional down quilt manufacturing process is long and inefficient.What's more,it also produces the problem of feather drilling out from fabric pores or pinholes with air.So it is necessary to develop a new kind of down quilt which is different from traditional down quilt.Driven by this trend,both Dream Cleaning Home Textile Co.,Ltd.and DongHua university.propose that the research and development of a new kind of down quilt need to be made.Studying of down quilt fabric in a lattice of double-layer structure or three-storey structure of integral weaving and forming which is skin friendly,thin,soft and comfortable,warm and has excellent downproofness.Under the guidance of the guiding ideology,this subject is developed in research and development of down quilt fabric with three enterprises including Zibo Silverman Textile Co.Ltd(weaving),Ningbo Vicotte Co.,Ltd.(finishing)and Suzhou letrie Household Articles Co.,Ltd.(finished product processing and testing).First of all,The processing method of traditional down quilt is improved in this thesis.The two processes of the fabric production and the sewing process in the traditional down quilt were merged into one process.The down quilt fabric of integral and forming was formed by use of weaving which reduces the sewing process and raises productivity.In the subject,by changing the stitch position of the traditional down quilt,and in a lattice of 9×9 of double-layer and a lattice of 7×8 of three-layer of down quilt fabric were made.In this thesis,the specification of the double-layer down quilt bedding is 248×248cm and the specification of threee-layer down quilt bedding is 200×230cm.The size of fabric and finished fabric of two kinds of down quilt is based on the specifications of the down quilt beddings.The commonly used tube size is 3.5cm in the enterprise,the reasonable cavity size is designed to be 4.5cm in order to ensure that feathers could be filled into the integral fabric smoothly and be distributed proportionally,achieving better effect of warm.In order to achieve the appearance of lattice,a weaving technology based on the double-layer and three-layer structure of down quilt fabric was presented.Reasonable cavity was realized by using double tubular tissue,and the longitudinal and transverse lines were achieved by junction double layer tissue,thus the appearance of the 9×9lattice of the double-layer structure was realized.As for down fabric of the three-layer structure,reasonable cavity was realized by using three tubular tissue,and the longitudinal lines was achieved by junction three layers of tissue,and transverse lines was realized by using junction double layer tissue,thus the appearance of the 7×8 lattice of the three-layer structure was realized.The weaving specification of the double-layer structure fabric is polyester DTY50D/48×Model 80~s compact spinning yarn×400/inch×278 root/inch;the weaving specification of the three-layer structure fabri is polyester DTY50D/48f ×JCF100~s+C40~s(2:1)×400 root/inch×460 root/inch.Grey fabric were made in the first trial production.Then,the process of desizing and bleaching of the double-layer structure and three-layers of down fabric is carried out in the finishing process.In order to ensure the downproofness of the fabric,positive and negative weight calendering process are made.Subsequently,the density testing and permeability testing of the finished products were made.At last,a series of process such as cloth cutting,overedging,pile filling and so on was made to product 40cm× 40cm of the down quilt bag in the process of finished products.And revolving box method is used to prevent the downproofness of the product.First trial production of down quilt fabric of double-layer structure of integral weaving and forming met some requirements,but the shortage is that after the calendering process,the fabric feel a little deviation,the down-penetration quantities of the sample was 65 which was more than 10,which did not reach the enterprise standard.In order to improve the downproofness of fabric,process parameters of weaving and finishing were regulated in second trial production.The warp fineness was changed into 35D/144f,and meridional tightness was reduced and zonal tightness was increased,and kinds of filling were increasesd including cotton,cotton/kapok blended yarn,and Tencel in weaving.Airflow softening process was made in finishing.9 samples were made in second trial production.The experimental results showed that the fabric becomes softer and the down-penetration quantities was reduced to 15,which was up to the national standard.First trial production of down quilt fabric of three-layer structure of integral weaving and forming met some requirements,but the shortage is that the fabric weaving efficiency was only 50%,which can not meet the basic requirements of the enterprise.And the transverse junction line strength was low after finishing.Cavity size of every down quilt was not same in cutting cloth in the finished product processing.the size of the cell was adjusted,the density of the weft was reduced,the material of weft yarn of the middle layer was changed,and the number of weft connection roots was increased in the second trial production.The experiment showed that the efficiency of weaving production was raised from 50% to 75%,and solved the problem of batch cutting and drawing during the processing of finished products,and the problem of low strength and easy to be torn of the transverse junction line.However the downproofness is need to be increased.By means of the design of the product,the optimization of the warp and weft yarn,the adjustment of the processing technology in the weaving,the adjustment of the finishing process,the improvement of the production efficiency and the improvement of the performance of the downproofness of the products,it is proved that it is feasible to produce double-layer structure and the three-layer structure down quilt fabric of integral weaving and forming.