Patent Application
20240150942
The present invention relates to the field of warp knitting machines, in particular to a warp knitting traverse device and warp knitting machine.
With the development of society and the advancement of science and technology, people have higher and higher requirements for the quality of fabrics used in clothing and home textiles. As a major attraction of autumn and winter clothing and home textile products, plush products have rich product selections and wide applications. People are not only satisfied with their appearance, comfort and warmth for plush products, but also pay more and more attention to their other potential attributes including possible environmental impact, functionality and safety of use, especially since the beginning of “14th Five-Year Plan”, driven by the policies of “carbon peak” and “carbon neutrality”, as well as in the current “post-pandemic” era, people are increasingly interested in adopting or in favor of purchasing plush products with new environmentally friendly renewable raw materials, raw materials with antibacterial or other functions, and bio-based raw materials in the plush. However, in the short term, it is difficult for these new raw materials to completely replace the common chemical fiber raw materials most used in the current plush products. In addition, in the actual daily use of plush products, people pay more and more attention to the safety of the products. Taking the hair loss of plush products as an example, the microchemical fibers debris can easily enter the human respiratory tract and cause various diseases. Unfortunately, given the scope of the existing technology, no complete solution for the hair loss issue of plush products.
For conventional plush products, taking warp knitted coral velvet fabric as an example, a knitted warp knitted bamboo charcoal coral velvet fabric and its processing method disclosed in patent CN101929030A. In this disclosure, the bottom wire is a 75D/36F polyester filament, the surface silk adopts a combination of 150D/288F polyester ultra-fine low elastic yarn and 150D/144F bamboo charcoal polyester modified yarn. Through traditional knitting process and post-processing, a finished fabric at 260-280 g/m2 can be finally obtained, of which bamboo charcoal polyester modified yarn accounts for 11.2%˜40.7%, the proportion of the bottom wire accounts for only 17-18.6%. This low ratio of the bamboo charcoal polyester modified yarn is actually for fabrics having a square gram weight below 280 g/m2. For the fabrics with a square gram weight above 300 g/m2, when proportion of the bottom wire will be even lower, relatively, and the ratio of bottom wire will be more difficult to reach 30-50% content. Further, when the functional bamboo charcoal polyester modified raw material is placed in the face yarn layer, on the one hand, because the difference in F number between of bamboo charcoal polyester modified yarn and polyester ultra-fine low elastic yarn is relatively large, it is easy to bring about a large difference in the suede feel of the face yarn layer, that is, the touch feel of the material is uneven and inconsistent; on the other hand, when functional bamboo charcoal polyester modified silk is used as the surface silk, in the finishing process, the fiber structure is very susceptible to damage, which will cause raw material loss and function sacrifice.
Another example is a super-dull PV fleece and its production process introduced by patent CN112176519A. The surface silk (plush silk) adopts the super-dull polyester filament of circular cross-section of 75D/36F, and the bottom thread adopts matt polyester low-elastic yarn with a cross-section of 75D/36F. Through knitted and processed by conventional processes, even under the condition that the base wire is thicker than the top wire, at the expense that the fabric base becomes thicker, the bottom plate becomes harder, and the fabric touch feel and style are also have subsequent changes, but the proportion of bottom silk still cannot reach more than 30%. Upon further research and investigation of the existing technology, based on the current conventional equipment and general process, both theoretical calculation and actual experimental practice showed that it is very challenging to achieve high proportion bottom wire in in plush fabric for high gram weight sizes, if not to change the fabric style and the ratio between different raw material thickness.
In addition, patent CN111041701A discloses a preparation process of fox fur-like fabric. By gluing a bottom DTY layer, the root of the acrylic yarn can be further firmly fixed on the DTY layer on the basis of knitting, thereby reducing the hair loss risk. However, the method of applying glue on the back is a chemical method. On one hand, it does not meet the requirements of environmental protection, and at the same time, it increases the production and processing steps and time. One the other hand, because the entire back is coated with a glue layer, it cannot be brushed, which limits the production of double-sided plush fabrics. Further, in the process of multiple washing and use in the later period, the glue is prone to aging or even peeling, resulting in a decrease in adhesion, and it is difficult to maintain the fixation effect on the face yarn for a long time.
Therefore, there is an urgent need for a technical solution that can increase the proportion of the core yarn without changing the style and feel of the existing product, and can permanently fix the face yarn through the physical structure so that it does not fall off easily.
The purpose of the present application is to provide a warp knitting traversing device and a warp knitting machine, which can break through the limitation of the existing four-stroke technology, realize six strokes, eight strokes, twelve strokes or twenty-four strokes, etc., and improve the stability and efficiency of knitting.
In order to achieve the above purpose, the application proposes the following technical solutions.
A warp knitting traverse device, comprising a faceplate and a yarn guide, the cross-section of the faceplate is an annular shape with unequal outer diameters, and the annular shape is equally divided into x number of section along a circumferential direction, wherein x is an integer and 2≤x≤8; at least two slopes are formed between adjacent sections.
In the prior art, due to the large gradient between the sections, the step span is too large, which will damage the machine, and is not conducive to the smoothness of the transverse movement of the yarn guide, thereby affecting the accuracy of the knitting fabric structure. The gradually gentle slope, disclosed in the present invention, is used for buffering, allowing the yarn guide to move step by step, which can avoid the instability caused by said large span, and is beneficial for high precision and stability in the production of fabrics by the warp knitting machine. Further the new invention reduces to risk the machine fault in the continuous production, which is also conducive to achieve the high speed of the manufacturing.
As a further improvement to the present application, the range of the push movement angle between adjacent sections is 7.5°-82.5°.
As a further improvement to the present application, a pressure angle of the slope surface ranges from 1 to 39°. Further, when two slopes are formed between adjacent sections, the pressure angle of any slope is in the range of 15° to 35°; further, when three slopes are formed between adjacent sections, the pressure angle of any slope is ranged between 10-15′; further, when four slopes are formed between adjacent sections, the pressure angle range of any slope is 5-10°; further, five slopes are formed between adjacent sections, the pressure angle of any slope surface ranges from 1 to 5°.
As a further improvement to the present application, a transition of the slope surface is arc-shaped to form an overall precise surface curve, which further improves the production smoothness and stability.
As a further improvement to the present application, the warp knitting traverse device comprises i number of yarn guides, number i is an integer and 5≤i≤8.
A warp knitting machine comprises the above-mentioned warp knitting traverse device.
The present application adopts a new stroke process to replace a traditional four-stroke process to produce warp knitted double needle-bed plush fabrics, which realizes that in the fabric, in the rectangular area formed by any continuous 2 (columns)×2 (wales), the number of core yarns N that are arranged in parallel along the same direction and cover the loops formed by the face yarn or core yarn is greater than 9. This breaks the limitation of the traditional process where a single maximum traverse movement can only allow 4 or 5 needles, which in turn cannot make the number of core yarns along the same direction more than 5 and 6. When the number of threads arranged in parallel in a same direction exceeds the limitation of 5 or 6, and the number of core yarns per unit area is increased, thereby solving the problems of low distribution density, low coverage and low proportion of core yarns in fabrics produced by traditional processes. At the same time, the present application can improve the production accuracy, achieve sustainable production, and can also greatly improve the production efficiency after testing, so that the production efficiency can be increased by 30-50%. Of course, the structural improvement of the present application is not only applicable to the production of plush fabrics, but can also be applied to other knitting articles and process, and is not limited to the plush fabrics described in this application.
A plush fabric, comprising a core yarn and a face yarn, the core yarn constitutes a core yarn layer, and the core yarn layer is located between the plush and the loop formed by the face yarn; at least one layer of the core yarn layers satisfies: in an unit area, the number of core yarns arranged in parallel along the same direction and covering the loops formed by the face yarn is N, and N≥9. The unit area refers to the rectangular area formed by any continuous horizontal two loops x vertical two loops.
The number of core yarns per unit area of the fabric disclosed by the present application is greatly increased, which can further reduce the issue of hair loss, thereby improving the lifetime and safety of final product.
As a further improvement to the present application, the mass of the core yarn accounts for 30-50% of the total mass of the plush fabric.
If the proportion of core yarn in the total plush fabric is too low: then proportion of face yarn is relatively high, and the wool surface appears relatively fuller, but when the proportion of core yarn is too low, on the one hand, if the core yarn layer is too thin, it will cause the fabric to be too soft and unstable, appears lacking body bones, lack of stiffness, more importantly, the ratio of core yarn is too low, the coverage density and clamping force of the yarn loop is not enough, it will be susceptible to cause hair loss problem, in addition, if the core yarn is made of functional fibers (such as antibacterial yarns) or environmentally friendly yarns and the proportion of core yarns is too low, which will affect the overall functionality and environmental protection of the fabric.
The proportion of core yarn is too high: although it can ensure to achieve of the fabric's functionality and the performance of environmental protection, the coverage and clamping fastness of the yarn loop will also be improved, but this will cause the core yarn layer of the fabric to be too thick (thickness is high), resulting in the middle base layer of the fabric feeling too thick and too hard, while the fabric plush layer (that is, the face yarn layer) is relatively thin (original plush fabric is to highlight the plush layer, doing so is to “put the cart before the horse”), and eventually lead to the poor fabric with less appealing overall style and feels.
After the inventor's numerous creative experiments and investigations, the optimum content of the core yarn is 30-50% in order to balance all the property requirements.
The process disclosed in the present invention can increase the proportion of the core yarn in the fabric by changing the production process structure without sacrificing the style and feel of the existing fabric, so that the proportion of the core yarn layer in the plush fabric is 30%˜50%. Especially for fabrics with a square gram weight at more than 300 g/m2, it is difficult for the general production process to achieve a ratio of core yarns higher than 30%, but the technical solution disclosed the present application can be suited to achieve this. In addition, due to the significant increase in the proportion of the core yarn and the significant optimization of the fabric knitting structure, the clamping and fixing fastness of the core yarn to the yarn has also been greatly improved, so that the lint rate of the product is reduced to less than 0.2%. The physical structure fixes the face yarn fluff, which can maintain the fixing effect of the face yarn fluff for a long time, thus greatly improving the durability and safety of the product during use.
As a further improvement to the present application, the square gram weight of the plush fabric is preferably to be 200-650 g/m2. A further preferred square gram weight is 250-650 g/m2. A more preferred squared gram weight is 300-650 g/m2. In plush fabrics, the higher the square gram weight, the more difficult it is to achieve a high proportion of core yarns. Relatively speaking, it is easier to achieve a high proportion of core yarns for fabrics with a square gram weight below 200 g/m2. But for a square gram weight more than 200 g/m2, especially 300 g/m2, due to technical limitations, it is difficult to achieve a core yarn ratio of more than 30% without scarifying the fabric style, raw material thickness ratio and production efficiency. The present invention teaches an improvement on the physical structure of fabric, the square gram weight can be significantly increased.
As a further improvement to the present application, the fineness of the core yarn is 45-166D (filament) or 32-120S (staple).
As a further improvement to the present application, the fineness of the face yarn and the fineness of the core yarn are in the range of 1-4. Further, the fineness of the face yarn is in the range of 2-4 in the ratio of the fineness of the face yarn to the fineness of the core yarn.
Compared with the face yarn, if the core yarn is too thick, that is, the ratio of the face yarn fineness to the core yarn fineness is less than 1 (that is, the core yarn is thicker than the face yarn), although the proportion of the core yarn is relatively high, in this case, it will cause the fabric having a core yarn layer too heavy and solid (too thick), which results in the middle base layer of the fabric feels too thick and too hard, while as the fabric plush layer (that is, the face yarn layer) is relatively thin (original plush fabric is to highlight the plush layer, so again “the cart before the horse is put upside down” scenario), resulting in a loss of the overall style and feel of the fabric;
Compared with the face yarn, if the core yarn is too fine, that is, the ratio of the face yarn fineness to the core yarn fineness is greater than 4 (that is, the core yarn is much thinner than the face yarn), the core yarn layer of the fabric is relatively thin, in this case, although the plush layer can be sufficiently prominent, but if the core yarn layer is too thin, the fabric will be too soft or even collapsed, suffer from an unstable shape, bearing no body bones, and having no stiffness. More importantly, if the core yarn is relatively too thin, during the knitting process, the face yarn being relatively too thick, the difference between the strength of the face yarn and the core yarn is too large, when knitting the two at the same time, the core yarn is relatively prone to yarn breakage, which leads to problems such as holes in the fabric, which greatly reduces the yield of success knitting passage of the fabric (poor knitting).
As a further improvement to the present application, the core yarn is filament or staple. Further, the filaments are differentiated filaments, and the staple fibers are bio-based fibers.
As a further improvement to the present application, the differentiated filament is modified polyester, regenerated polyester, functional polyester or chemical fiber filament with special-shaped cross-section. Further, the special-shaped section filaments are triangular section filaments or hollow section filaments. If the triangle and the hollow are used for the face yarn, the hand feeling will be relatively poor, but if the two are used for the core yarn, the problem of the poor hand feeling of the face yarn can be avoided, while retaining the advantages of the face yarn and the core yarn.
As a further improvement to the present application, the bio-based fiber is hygroscopic exothermic viscose, lyocell, triacetic acid or SORONA (Solona). When these staple fibers are used in face yarns, they have poor touch feel and excessive loss, but when they are used in core yarns, the problems of poor touch feel, and large losses of face yarns can be avoided while retaining their advantages.
The core yarn of the present application is a new type of raw material such as modified polyester, regenerated polyester, functional polyester, and bio-based fiber. By placing this environmentally friendly material in the core yarn layer, on one hand, it is beneficial to environmental protection, and on the other hand, through the present application, an unique knitting structure can make the core yarn layer material have a higher clamping fastness to the surface layer plush fabric, thereby greatly improving the hair loss problem without sacrificing the style and feel of the existing product. In addition, this new type of fabric is prone to problems such as raw material loss and function decline during the post-finishing process, and the application is placed in the core yarn layer to avoid the above problems.
As a further improvement to the present application, the plush length on the surface of the plush fabric is 3-15 mm. Short hair height means that the proportion of face yarn is relatively small, and the proportion of core yarn is relatively high, but the application highlights that, in addition to the short hair height, in the case of long hair height in other ranges, the technical solution disclosed by the present invention can still achieve the high proportion of core yarn.
After testing, the hair loss rate of the plush fabric is less than 0.15%, the transverse shrinkage rate is 0-0.4%, and the longitudinal tear strength is greater than 29.4N. The longitudinal tear strength of the fabric of the present application is higher than that of the ordinary plush fabric, and the transverse shrinkage rate is smaller, indicating that the present application has good wear resistance and tear resistance, dimensional stability and shape retention, and does not produce weft skew, suitable for everyday use.
The preparation method of the above-mentioned plush fabric includes the step of on-machine knitting. During knitting, the number of said yarn guides is i, 5≤i≤8; at least four yarn guides are used to configure core yarns, and at least one yarn guide is used for configuring the face yarn.
Furthermore, the yarn guides GB1 to GB3 and GBi-2 to GBi are used to configure the core yarns.
Furthermore, the yarn guides GB1, GB2 and GBi-1, GBi are used to configure the core yarn.
Further, its knitting process can be:
Beneficial Effects:
1. The present application adopts a warp knitting traversing device with a faceplate having at least two or more gentle transitional gradients, which is beneficial to achieve high precision, smoothness and high speed of production.
2. The warp knitting traversing device of the present application enables the warp knitting machine to realize six strokes or eight strokes, twelve strokes, and twenty-four strokes, thereby breaking through the limitations of traditional techniques and achieving the inconvenience in fabrics that cannot be achieved by traditional techniques. In the rectangular area formed by any continuous 2 (sections)×2 (wales), the number of core yarns arranged in parallel along the same direction is N and N≥9. Further, using the process disclosed in the present application, it can make the proportion of core yarns in the fabric reach 30-50%, especially for fabrics with a high square gram weight above 300 g/m2 can also achieve such a high proportion (the prior art). It is difficult to make the high gram weight fabric core yarn account for more than 30%. Moreover, the realization of the high proportion of the core yarn in the present application does not come at the expense of the style, quality and production efficiency of the fabric, and the knitted organizational structure of the process can also effectively fix the face yarn plush for a long time.
3. In this application, new environmentally friendly or functional raw materials are placed on the core yarn layer instead of on the surface layer, and the proportion of the new material is not less than 30%. On one hand, by doing so, it can ensure that the new fabric material is environmentally friendly or functional; on the other hand, compared with conventional face yarn raw materials, the new functional materials exhibits great differences in monofilament fineness, yarn strength, dyeing and coloring, etc., and when they are placed in the core yarn layer, it is greatly reduces their unfriendly impact on the style and feel of the fabric. In addition, during the finishing process, the environmentally friendly or functional raw materials located in the core yarn layer are not easily damaged, and there is almost no loss, thereby minimizing the loss and maximizing the function. In addition, placing environmental protection or functional raw materials in the core yarn layer does not limit the choice of face yarn, thus achieving a great diversification of products.
4. The application adopts an innovative process structure, which effectively improves the transverse shrinkage rate and longitudinal tear strength of the fabric. Its longitudinal tear strength is about 2 to 3 times that of traditional craft fabrics, which can reach more than 29.4N. In the process of fabric processing and later use, it is not easy to cause problems such as fabric damage and fabric breakage due to low tear strength, thereby reducing the number of fabrics loss. In addition, the lateral dimensional stability of the fabric is extremely superior. Under the condition of multiple washings, its lateral shrinkage rate can be maintained at 0-0.4%, which has a significant advantage compared with the 1-3% lateral shrinkage rate of traditional craft products. The daily use performance of the product is improved, the product has better shape retention, and it is not easy to wrinkle and weft.
It is to be understood that all combinations of the foregoing concepts, as well as additional concepts described in greater detail below, are considered to be part of the inventive subject matter of the present disclosure to the extent that such concepts are not contradictory.
The foregoing and other aspects, embodiments and features of the teachings of the present application can be more fully understood from the following description when taken in conjunction with the accompanying drawings. Other additional aspects of the present application, such as features and/or benefits of the exemplary embodiments, will be apparent from the description below, or learned by practice of specific embodiments in accordance with the teachings of the present application.
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by the same reference numeral. For clarity, not every component is labeled in every figure. Embodiments of various aspects of the present application will now be described by way of example and with reference to the accompanying drawings, wherein:
In the figures, 1 is the transition point, α1 is the pressure angle of the prior art, β1 is the push movement angle of the prior art, α21 and α22 are the pressure angles of Embodiment 1, and β2 is the push movement angle of Embodiment 1.
In order to make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are some, but not all, embodiments of the present application. Based on the described embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application. Unless otherwise defined, technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this application belongs. “First”, “second” and similar words used in the patent application description and claims of the present application do not indicate any order, quantity or importance, but are only used to distinguish different components. Also, unless the context clearly dictates otherwise, the singular forms “a,” “an,” or “the” and the like do not denote a limitation of quantity, but rather denote the presence of at least one. Words like “including” or “comprising” mean that the elements or items appearing before “including” or “including” cover the features, integers, steps, operations, elements and/or recited after “including” or “including” or components, does not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or sets thereof. “Up”, “Down”, “Left”, “Right”, etc. are only used to indicate relative positional relationship, and when the absolute position of the described object changes, the relative positional relationship may also change accordingly.
The present application discloses a plush fabric and a preparation method thereof. By increasing the number of core yarns per unit area, the problem of hair loss is reduced, thereby improving the durability and safety of product use.
In order to realize the above changes, the present application also discloses a warp knitting machine, which is mainly used for producing the plush fabric by improving the warp knitting traverse device.
A plush fabric, comprising a core yarn and a face yarn, the core yarn constitutes a core yarn layer, and the core yarn layer is located between the plush and the loop formed by the face yarn; at least one layer of the core yarn layer satisfies: In a unit area, the number of core yarns arranged in parallel along the same direction and covering the loops formed by the face yarn is N≥9. The unit area refers to any continuous horizontal two loops×two vertical loops. a rectangular area (as shown in
In some embodiments, the mass of the core yarn accounts for 30-50% of the total mass of the plush fabric.
In some embodiments, the fineness of the core yarn is 45-166D or 32-120S.
In some embodiments, the ratio of the fineness of the face yarn to the fineness of the core yarn is in a range 1-4. In at least one embodiment, the fineness of the face yarn to the ratio of the fineness of the core yarn is in the range of 2-4.
In some embodiments, the core yarn is filament or staple.
In at least one embodiment, the filaments are modified polyester, recycled polyester, functional polyester or profiled cross-section filaments. In at least one embodiment, the profiled-section filaments are triangular-section filaments or hollow-section filaments.
In at least one embodiment, the staple fibers are bio-based fibers. In at least one embodiment, the bio-based fibers are hygroscopic exothermic viscose, lyocell, triacetate, or SORONA.
In some embodiments, the face yarn is a chemical fiber filament, including ordinary chemical fiber filament or modified chemical fiber filament; it can be original filament or regenerated filament; it can be ordinary white filament or ordinary white filament. It is a dope dyed colored yarn; it can be a single-component filament or a multi-component composite filament. The foregoing examples are merely illustration and should not be construed as a limitation.
In some embodiments, the unit square gram of the plush fabric is 300-650 g/m2.
In some embodiments, the plush length of the plush fabric surface is 3-15 mm.
The preparation method of the plush fabric includes the following steps: warping of face yarn, warping of core yarn→knitting on machine→slitting of grey fabric→carding of grey fabric→ironing of grey fabric→pre-forming of grey fabric→dyeing of grey fabric (except for yarn-dyed knitting, which is not required dyeing), softening→drying of colored cloth→colored cloth (except for single-sided plush, which does not need to be brushed)→colored cloth blowing (mainly for wool-like products, and other products can be selectively blown or not blown)→colored cloth combing→colored cloth ironing→colored cloth shearing→colored cloth shaking→colored cloth finished product prototypes.
During the knitting process, the number of the yarn guides is i, and 5≤i≤8. Specifically, when i=5, GB1, GB2, GB4, and GB5 configure core yarns; when i=6, GB1, GB2, GB5, and GB6 configure core yarns; when i=7, GB1, GB2, GB6, and GB7 configure core yarns or GB1, GB2, GB3 and GB5, GB6, GB7 configure core yarn; when i=8, GB1, GB2, GB3 and GB6, GB7, GB8 configure core yarn.
In some embodiments, the upper machine knitting adopts six strokes, and the knitting process of the six strokes is:
In some embodiments, the upper machine knitting adopts eight strokes, and the knitting process of the eight strokes is:
The above N is a positive integer, and
A warp knitting machine includes a machine tool body, a warp knitting traverse device and a transmission mechanism. The warp knitting traverse device is located on the main body of the machine tool, and is connected with the transmission mechanism through a main shaft, turbine reducer and other devices. The transmission mechanism is used for the warp knitting traverse device to control the movement of the yarn guide to generate traverse, so as to knit a corresponding knit structure and form different fabric patterns.
The warp knitting traverse device includes a face plate, a push rod and a yarn guide bar. A plurality of faceplates is mounted on the main body of the machine tool through shafts, one end of the push rod is in contact with the outer surface of the faceplate, and the other end of the push rod is connected with the yarn guide bar. Due to the different ups and downs on the outer surface of the faceplate, when the faceplate rotates, the push rods that were push against to the faceplate and vice versa will move laterally, thereby driving the yarn guides on the push rods to move laterally, forming the designed knitting process. The faceplate is an integrated structure, and the integrated structure is more conducive to the stability and sustainability of the warp knitting traverse device. Of course, the faceplate is not limited to the above-mentioned integrated structure, and may also be composed of a plurality of chain blocks of different shapes and sizes. The number of the faceplate is generally equal to the number of yarn guides used, at least two (two yarn guides are generally used for a single needle-bed machine to work with two rolls of plush wires).
In order to better disclose the present application, the solutions of the prior art are introduced below for comparison.
The warp knitting traversing device of the present application, through the improvement of the faceplate, breaks through the limitation that core yarns cannot be arranged in parallel in the same direction in a rectangular area composed of any continuous 2 (sections)×2 (wales) in the traditional process. If the number exceeds 5 or 6, it can solve the problems of insufficient core yarn distribution density, low coverage and low proportion of fabrics produced by traditional processes, especially fabrics with a high square gram weight above 300 g/m2. details as follows: Warp knitting traversing device, the cross section of the faceplate is an annular shape with unequal outer diameters, and the annular shape is equally divided into x sections along the circumferential direction, where 2≤x≤8; on the outer surface of the faceplate, at least two slopes are formed between adjacent sections.
In some embodiments, the range of push movement angle between adjacent sections is 7.5°˜82.5°. The pressure angle of the slope surface ranges from 1 to 39°.
Specifically, in the case of six strokes, two slope surfaces are formed between adjacent sections, and the pressure angle of any slope surface is in the range of 15 to 35°; in the case of eight strokes, three slope surfaces are formed between adjacent sections, and any slope is formed between two slopes. The pressure angle of the surface ranges from 10 to 15°; for twelve strokes, four slopes are formed between adjacent sections, and the pressure angle of any slope ranges from 5 to 10 degrees; for twenty-four strokes, five or more slopes are formed between the adjacent slopes, and the pressure angle of any slope ranges from 1 to 5°.
In some embodiments, the transition of the slope surface is arc-shaped, so as to form an overall precise surface curve (arc-shaped surface), so that the movement of the yarn guide is smoother and more precise.
In some embodiments, the number of yarn guides is i, and 5≤i≤8.
In the prior art, due to the large gradient between the sections, the step span is too large, which will damage the machine, and is not conducive to the smoothness of the transverse movement of the yarn guide, thereby affecting the accuracy of the organizational structure; a gradually gentle slope is used for buffering, allowing the yarn guide to move step by step. Through at least two or more steps of transmission, any possible instability caused by the large span can be avoided, which is beneficial to achieving high precision and smoothness in the process of fabric production using the current warp knitting machine, further to reduce fault loss of the machine during continuous production and achieve the high throughput operation.
The present application will be further described in detail below with reference to specific embodiments. Embodiments 1-3 illustrate the improvement of the faceplate of the present invention. Embodiments 4-7 illustrate the plush fabric of the application, and Embodiments 8-9 illustrate the production process of the plush fabric of the application.
The faceplate is equally divided into 8 sections along the circumferential direction. The transition point 1 of the slope surface can be a straight transition as shown in the figure, or it can be a transition of an arc surface, which is more smooth.
On the outer surface of the faceplate, two slopes are formed between adjacent sections, and the pressure angles α21 and α22 of the slopes are both between 15° and 35°, while the push movement angle β2 between adjacent sections is between 7.5 and 82.5°.
The faceplate is equally divided into 6 sections along the circumferential direction. On the outer surface of the faceplate, three slopes are formed between adjacent sections, and the pressure angles of the slopes are respectively between 10 and 15°, while the push movement angle between adjacent sections is between 7.5 and 82.5°.
The faceplate of this embodiment is equally divided into 4 sections along the circumferential direction. On the outer surface of the faceplate, four slopes are formed between adjacent sections, and the pressure angles of the slopes are respectively between 5 and 10°, while the push movement angle between adjacent sections is between 7.5 and 82.5°.
The warp knitting traverse device of the present application is provided with a plurality of gentle inclination angles, which can reduce the impact and increase the movement speed. Even if the length of a single section is increased, it will cause an unstable operation, it can still achieve six strokes or eight strokes, and so on, further to be twelve strokes, twenty-four strokes, etc., which can reach at least the displacement of the two-stage transmission yarn guide, which conserves the equipment.
A plush fabric has a core yarn layer in a unit area that satisfies the following conditions. The core yarns are arranged in parallel in the same direction and cover the loops formed by the face yarn, the number of said face yarn N=9.
The mass of the core yarn accounts for 30% of the total mass of the plush fabric.
The core yarn is a modified polyester filament, and the cross section of the filament is a hollow cross section. The fineness of the core yarn is 45D.
The fineness ratio of the face yarn to fineness of the core yarn is 2.67, that is, the face yarn adopts 120D/192F.
The gram weight of the plush fabric is 300 g/m2.
A plush fabric has a core yarn layer in a unit area that satisfies the following conditions. The core yarns are arranged in parallel in the same direction and cover the loops formed by the face yarn N=11.
The mass of the core yarn accounts for 38% of the total mass of the plush fabric.
The core yarn is regenerated polyester filament. The fineness of the core yarn is 100D.
The fineness of the face yarn is 1.5 folds to the fineness of the core yarn. That is, the face yarn is made of 150D/228F dope dyed polyester DTY low elastic yarn. The gram weight of the plush fabric is 450 g/m2.
A plush fabric with two core yarn layers in a unit area satisfies the following conditions. The core yarns are arranged in parallel in the same direction and cover the loops formed by the face yarn N=11.
The mass of the core yarn accounts for 50% of the total mass of the plush fabric.
The core yarn is short fiber, and further the short fiber is SORONA. The fineness of the core yarn is 72S.
The fineness of the face yarn is 1 in ratio to the fineness of the core yarn. That is, the face yarn is made of 75D super matt flat FDY filament.
The gram weight of the plush fabric is 315 g/m2.
A plush fabric with three core yarn layers in a unit area satisfies the following conditions. The number of core yarns arranged in parallel in the same direction and covering the loops formed by the face yarn is N=12.
The mass of the core yarn accounts for 45% of the total mass of the plush fabric.
The core yarn is short fiber, and further the short yarn is hygroscopic and exothermic viscose.
The fineness of the core yarn is 32S.
The fineness of the face yarn is 2 in the ratio of the fineness of the core yarn. That is, the face yarn is made of 330D cationic and polyester composite yarn.
The gram weight of the plush fabric is 580 g/m2.
After testing, the hair loss rate of the plush fabrics of Embodiments 4-7 is less than 0.15%, the transverse shrinkage rate is 0-0.4%, and the longitudinal tear strength is greater than 29.4N.
The production process of a plush fabric includes the following processes.
A. Face yarn: 150D/228F dope dyed regenerated polyester yarn and 150D/288F ordinary white silk, the two kinds of raw materials are respectively configured on two velvet yarn guides or combined on two velvet yarn guides according to certain rules, to form different color and pattern combinations.
B. Core yarn: 40S lyocell staple fiber. The raw material for the production of the yarn is the inexhaustible natural plant cellulose in nature. The production process does not involve chemical reaction, the solvent used is non-toxic, and the solvent recovery rate can be as high as 99.7%. In addition, the process of making Lyocell does not release harmful gases such as carbon disulfide and hydrogen sulfide during the processing and manufacturing process, and is a low-carbon, energy-efficient and environmentally friendly green fiber. In addition, Lyocell itself has the characteristics of high strength, basically no shrinkage, and excellent hygroscopicity, moisture permeability, air permeability, and no static electricity. It is an environmentally friendly fiber raw material.
A. Face yarn: SGZ400D intelligent computer control warping machine, pan head specification: “Φ21X21”; number of warping heads: 432; warping speed 1200 rpm; single yarn warping tension: 15˜16 cN.
B. Core yarn: SGZ300D computer-controlled high-speed warping machine, pan head specification: “Φ21X21”; number of warping heads: 432; warping speed 1500 rpm; single yarn warping tension: 9˜11 cN.
(3) Upper machine knitting: RD6 DPLM plush double needle-bed warp knitting machine equipped with 6 yarn guides, machine size: E20; machine width: 138 inches; modification of the warp knitting traverse device of the warp knitting machine: the four-stroke process is changed to the six-stroke process of Embodiment 1 to meet the product requirements.
A. Threading:
GB1, GB2, GB5, and GB6 are all equipped with 40S lyocell staple fiber, which can be fully worn.
GB3: Equipped with 150D/228F dope dyed regenerated polyester yarn and 150D/288F ordinary white yarn, which is half-wearing and one-wearing.
GB4: Equipped with 150D/228F dope dyed regenerated polyester yarn and 150D/288F ordinary white yarn, which is half-wearing and one-wearing.
B. Knitting:
According to the following knitting process
Let-off amount: 6100 mm/rack;
Let-off amount: 2320 mm/rack;
Let-off amount: 28850 mm/rack;
Let-off amount: 28850 mm/rack;
Let-off amount: 2320 mm/rack;
Let-off amount: 6100 mm/rack.
The gap between the front and rear needle-beds is set to 29 mm, the pulling density is 10.5 cpc, and the startup speed is 980 rpm (the startup speed of conventional equipment is 700-800 rpm).
(4) Slitting of Grey Cloth:
The double-layer grey fabric knitting in the previous process is slitted through a vertical slitting machine, and the gross height and gram weight on both sides are controlled to be consistent, thereby obtaining a two-sided single-layer colored grey fabric.
(5) Processing after Dyeing and Finishing:
Combing of colored grey fabrics: The fluffs that are entangled on the cloth surface are preliminarily combed, and the foreign fibers and other impurities on the cloth surface can be removed at the same time;
Softening on the color cloth: using the rolling car, the softening agent and the smoothing agent are mixed with the third-grade water according to the concentration of 30-60 g/L, poured into the rolling groove, and the two-dipping and two-rolling method is adopted, and the speed of the softening is controlled at 5-15M/min, dehydrate the color cloth after softening;
According to the above process, the final fabric is obtained, the finished product gram weight is: 635 g/m2, the wool height is 13.5 mm, the veil accounts for 65%, and the core yarn accounts for 35%. In the unit area constituted by the line), the number of the core yarns arranged in parallel in the same direction and covering the loops formed by the face yarns is 9 or 10. The fabric is tested by In-House Test Method 019 standard: lint rate 0.11%, transverse washing shrinkage 0.2%, longitudinal tear strength 43.5N, tested by AATCC76:2011 standard, the fabric resistivity is 1.05X10752, there is obvious Antistatic effect, and the fabric does not involve chemical dye dyeing process in the production and processing process, and saves water and water, making the product more healthy and environmentally friendly concepts and attributes.
The production process of a plush fabric includes the following processes:
(1) Raw Material Selection
A. Face yarn: 150D/288F full extinction, “one-word” flat cross-section DTY polyester filament. The raw material is elegant and soft in luster, delicate and soft to the touch, and is especially suitable for plush products.
B. Core yarn: 75D/72F semi-dull, circular section FDY coffee yarn. The raw material uses daily waste “coffee grounds”, uses polyester as the carrier, uses nano-processing technology, is activated at high temperature, and combines with “nano antibacterial silver ions” to form nano-scale holes on the surface and inside of the yarn, which can absorb odor, Reduce the concentration of harmful gases in the air. And the distribution of nano-silver ions in the yarn reaches more than 500 ppm, which has a long-lasting antibacterial function.
(2) Yarn Warping
A. Face yarn: SGZ400D intelligent computer control warping machine, pan head specification: “Φ42X21”; number of warping heads: 498; warping speed 1200 rpm; warping tension: 15˜16 cN.
B. Core yarn: SGZ300D computer-controlled high-speed warping machine, pan head specification: “Φ21X21”; number of warping heads: 498; warping speed 1500 rpm; warping tension: 8˜9 cN.
(3) Upper machine knitting: RD5 DPLM plush double needle-bed warp knitting machine equipped with 5 bars, machine number: E22; machine width: 110 inches; Transformation, the four-stroke process is changed to the eight-stroke process of Example 2 to meet the product requirements.
A. Threading:
FDY coffee yarn, fully worn.
B. Knitting:
According to the following knitting process
Let-off amount: 6710 mm/rack;
Let-off amount: 2130 mm/rack;
Let-off amount: 13260 mm/rack;
Let-off amount: 2130 mm/rack;
Let-off amount: 6710 mm/rack.
The gap between the front and rear needle-beds is set to 11 mm, the pulling density is 11.5 cpc, and the startup speed is 1050 rpm (the startup speed of conventional equipment is 700-800 rpm).
(4) Slitting of Grey Cloth:
The double-layer grey fabric knitting in the previous process is slitted through a vertical slitting machine, and the gross height and gram weight of both sides are controlled to be consistent, thereby obtaining a two-sided single-layer grey fabric.
(5) Processing after dyeing and finishing:
According to the above process, the final fabric is obtained. The finished product has a gram weight of: 380 g/m2, a wool height of 5 mm, 59% of the veil, and 41% of the core yarn. In the fabric, any continuous 2 (section)×2 (whole section), the number of the core yarns arranged in parallel in the same direction and covering the loops formed by the face yarns is 9 or 10. The fabric is tested by In-House Test Method 019: lint rate 0.11%, transverse washing shrinkage 0.2%, longitudinal tear strength 35.7N, tested by ASTM2149 standard, for Staphylococcus aureus, Escherichia coli, Streptococcus pneumoniae The antibacterial rate can reach more than 96%.
In the present application, the process in which the knitting needles complete a yarn laying action next time is a section. The distance of the faceplate covered by a yarn-laying action is one stroke.
The present application innovatively uses the six-stroke or eight-stroke process to produce the warp-knitted double needle-bed plush fabric, which realizes that in the fabric, in the rectangular area formed by any continuous 2 (columns)×2 (wales), there are core yarns in the same direction. The number of N≥9 that are arranged in parallel and cover the loops formed by the veil or core yarn breaks through the traditional process because the single maximum traverse movement can only reach 4 or 5 needles and cannot make the core yarn parallel in the same direction The number of distributed arrangement exceeds the limitation of 5 or 6, which solves the problems of insufficient distribution density and low coverage of fabric core yarns produced by traditional processes. In addition, the use of six-stroke or eight-stroke process to replace the traditional four-stroke process to produce warp-knitted double-needle-bed plush fabrics is conducive to the realization of high precision and stability of the warp knitting machine in the process of fabric production, and is conducive to protecting the machine for continuous production. Production is also conducive to realizing the high-speed of the machine and improving the production efficiency by 30% to 50%.
In this application, a new type of raw material is partially applied to plush products. As the core yarn layer (inner layer) of plush fabrics, on the one hand, it is beneficial to environmental protection. The layer (surface) pile has a higher clamping fastness, which can greatly improve the problem of lint.
After repeated tests in this application, it is found that when the proportion of the raw material quality of the core yarn layer in the plush fabric is 30-50%, the comprehensive effect is the best, which can greatly improve the hair loss problem without affecting the appearance of the plush fabric. Some feel.
The fabric of the present application is processed by physical structure innovation instead of chemical method, which can greatly reduce the problem of hair loss, thereby improving the durability and safety of the product during use.
The fabric part of the present application adopts environmentally friendly or functional raw materials, which can maximize the impact on the style and feel of the fabric while ensuring the embodiment of its environmental protection or functionality, and can solve the problem of raw materials in the post-finishing process. loss, functional degradation, etc.
The plush fabric produced by the innovative process in this application has a longitudinal tear strength that is about 2 to 3 times that of the traditional process fabric, and can reach 29.4N. In the process of fabric processing and later use, it is not easy to occur due to low tear strength. fabric damage, broken fabrics, etc. In addition, the lateral dimensional stability of the fabric is extremely superior. Under the condition of multiple washings, its lateral shrinkage rate can be maintained at 0-0.4%, which has a significant advantage compared with the lateral shrinkage rate of traditional craft products of 1-3%. Thereby improving the daily performance of the product.
There are other alternatives, which can also be included in the invention of the present application, but it is not a preferred solution. This alternative has low feasibility and high equipment requirements, and there are few such equipment on the market, which is not suitable for industrial production, and It will also affect the style and feel of existing products.
Although the present application has been disclosed above with preferred embodiments, it is not intended to limit the present application. Those with ordinary knowledge in the technical field to which this application pertains can make various changes and modifications without departing from the spirit and scope of this application. Therefore, the scope of protection of the present application should be determined by what is defined in the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202111303393.X | Nov 2021 | CN | national |
