Process for manufacturing super-high-count ramie fabric and the fabric
The present invention relates to a process for manufacturing a ramie fabric and the fabric. The process comprising the following steps: blend spinning a high-count ramie fiber such as a ramie fiber of 2500 Nm or higher with a water-soluble fiber as carrier to form a yarn; sizing the yarn at a low temperature; weaving the yarn to form a gray fabric; then removing the water-soluble fiber from the gray fabric by deweighting the gray fabric during a printing and dyeing finishing process to obtain a super-high-count ramie fabric with a ramie yarn fineness of 160 Nm or higher.
1. A process for manufacturing a ramie fabric, including the following steps:
blend spinning a ramie fiber of 2500 Nm or higher by using a water-soluble fiber as a carrier to form a yarn, the water-soluble fiber is of 6000 Nm or higher;
sizing the yarn at a low temperature and then weaving the yarn into a gray fabric;
removing the water-soluble fiber from the gray fabric by deweighting the gray fabric during a printing and dyeing finishing process to obtain a ramie fabric with a ramie yarn fineness of 160 Nm or higher; and wherein the printing and dyeing finishing process comprises the steps of turning and sewing up, then singeing, then deweighting, then bleaching, whitening and softening, stentering, and winding, and the step of deweighting comprises using an alkali desizing and scouring solution in a jet-overflow dyeing machine to thoroughly remove the sizing agents and the water-soluble fiber.
2. The process according to claim 1 , wherein the water-soluble fiber is between about 6000 Nm -8000 Nm .
3. The process according to claim 1 , wherein the water-soluble fiber has a water-dissolving temperature of 95° C. or lower.
4. The process according to claim 1 , wherein the step of blend spinning the ramie fiber with the water-soluble fiber as carrier comprises subjecting the water-soluble fiber and the ramie fiber to the steps of pre-drawing, drawing, roving and spinning to obtain a blended yarn of the ramie fiber and the water-soluble fiber.
5. The process according to claim 4 , wherein the dry-weight blending ratio of the ramie fiber to the water-soluble fiber in the blended yarn is 20-70:80-30.
6. The process according to claim 4 , wherein the step of drawing is performed by drawing the pre-drawn water-soluble fiber and the pre-drawn ramie fiber for at least 4 times, using a drawing process with 4 or more routes, and adopting a total draft ratio of 8-10.
7. The process according to claim 4 , wherein the step of roving is performed by using a roving process with two routes and adopting a total draft ratio of 7-9.5.
8. The process according to claim 4 , wherein the step of spinning is performed by adopting a total draft ratio of 10-40, a twist factor of 100-130, and a twist degree of 800-1200 twist/m.
9. The process according to claim 1 , wherein the step of sizing the yarn at low temperature is performed at a temperature of 95° C. or lower.
10. The process according to claim 1 , wherein the step of sizing the yarn at low temperature is performed by using a sizing solution comprising a polyvinyl alcohol, a modified starch and an acrylic sizing agent.
11. The process according to claim 10 , wherein the step of sizing the yarn at low temperature is performed by using a sizing solution comprising a polyvinyl alcohol of 5-20 g/L, a composite multi-component modified starch of 10-25 g/L, an oxidized starch of 30-40 g/L, and an acrylic sizing agent of 1-8 g/L.
12. The process according to claim 1 , wherein the step of deweighting comprises placing the singed fabric in a jet-overflow dyeing machine, heating to a temperature of 110-120° C., keeping the temperature for 15-20 minutes, washing the fabric in a bath of an alkali desizing and scouring solution, discharging the fabric, washing with hot water of 90° C. or higher twice, each for 10 minutes, and washing with cold water once.
13. The process according to claim 1 , wherein the alkali desizing and scouring solution comprises sodium hydroxide of 1-5 g/L, sodium carbonate of 0.2-1.5 g/L, sodium sulfite of 1-5 g/L and non-ion surfactant Peregal-O 0.2-1.5 g/L, relative to per liter of clear water.
14. The process according to claim 1 , wherein the bath ratio of the alkali desizing and scouring solution is 1:20.
15. The process according to claim 1 , wherein the water-soluble fiber is one or more water-soluble fibers selected from vinylon fiber, alginate fiber and carboxymethylcellulose fiber.
16. The process according to claim 1 , wherein after the step of blend spinning the ramie fiber and the water-soluble fiber as carrier to form the yarn, the blended yarn is further blend spun with one or more additional non-water-soluble fibers and then woven into a gray fabric.
17. The process according to claim 16 , wherein the additional non-water-soluble fibers comprise one or more fibers selected from cotton fiber, hemp fiber, wool fiber, silk fiber, viscose fiber, polyester fiber, polyamide fiber, acrylic fiber, polyurethane fiber, polypropylene fiber, polyvinyl alcohol fiber and aramid fiber.
18. The process according to claim 1 , wherein the water-soluble fiber is unacetalized vinylon fiber.