Anti-pilling knitted fabric and production process thereof

Abstract

The invention relates to the technical field of knitted fabrics, and provides an anti-pilling knitted fabric, which comprises an anti-pilling surface layer, a middle layer for increasing the elasticity and extensibility of the knitted fabric, and a bottom layer for increasing the air permeability and comfort of the knitted fabric, the surface layer is formed by weaving polytetrafluoroethylene fibers, the middle layer is formed by weaving spandex fibers, and the bottom layer is formed by weaving spandex fibers. The surface layer is formed by weaving cotton fibers, the middle layer is formed by weaving cotton fibers, the bottom layer is formed by weaving cotton fibers, the surface layer accounts for 20-30%, the middle layer accounts for 40-50%, the bottom layer accounts for 20-30%, and hot melt adhesive films used for bonding and fixing are arranged between the surface layer and the middle layer and between the middle layer and the bottom layer. By means of the technical scheme, the problems that in the prior art, the anti-pilling effect depends on physical mixing of fibers to a large extent, and friction between the fibers and burrs on the surfaces of the fibers still possibly cause generation of pilling are solved.

Description

Technical Field

[0001] The invention relates to the technical field of knitted fabrics, and in particular to an anti-pilling knitted fabric and a production process thereof. Background Art

[0002] Knitted fabrics are a type of textile widely used in clothing, home textiles and industrial fields. They are favored by consumers and manufacturers for their good softness, elasticity and breathability. The production process of knitted fabrics usually involves the weaving of yarns. This weaving structure not only gives the fabric an excellent feel and comfort, but also makes it have a certain degree of elasticity and fit. However, knitted fabrics are easily affected by friction during use and washing, resulting in the appearance of hairiness on the fiber surface and further the formation of pilling, which not only affects the appearance of the fabric, but also may reduce its service life.

[0003] In response to this problem, the textile industry has developed a variety of anti-pilling technologies, among which blending technology is widely used. By blending and weaving fibers with different properties, it is attempted to utilize the characteristics of each fiber material to complement each other, thereby improving the anti-pilling ability of the fabric. For example, the invention with publication number CN104452068A discloses an anti-pilling polyester-cotton blended knitted fabric, which is formed by blending and weaving polyester fiber, apocynum fiber, tencel fiber, etc. with cotton fiber, pineapple leaf fiber, Vicat fiber, etc. to form a multifunctional fabric, and the anti-pilling effect is enhanced by physical mixing of fibers.

[0004] However, although this method improves the anti-pilling performance of knitted fabrics to a certain extent, it still has some shortcomings. First, the anti-pilling effect of the prior art depends largely on the physical mixing of fibers. The friction between fibers and the burrs on the fiber surface may still lead to the formation of pilling. Secondly, due to the complex blending ratio and mixing method of the fibers, it is difficult to achieve precise control of the properties of each fiber during the production process, resulting in an unstable anti-pilling effect. In particular, after long-term use or repeated washing, the anti-pilling performance of the fabric may be significantly reduced. Summary of the invention

[0005] The invention provides an anti-pilling knitted fabric and a production process thereof, so as to better solve the problem that the knitted fabric is easy to pilling and provide a more durable and stable anti-pilling effect.

[0006] The technical solution of the present invention is as follows: A pilling-resistant knitted fabric comprises a pilling-resistant surface layer, a middle layer for increasing the elasticity and stretchability of the knitted fabric, and a bottom layer for increasing the air permeability and comfort of the knitted fabric. The surface layer is woven from polytetrafluoroethylene fibers twisted into polytetrafluoroethylene yarns, the middle layer is woven from spandex fibers twisted into spandex yarns, and the bottom layer is woven from cotton fibers twisted into cotton yarns. The surface layer accounts for 20%-30%, the middle layer accounts for 40%-50%, and the bottom layer accounts for 20%-30%. Hot-melt adhesive films for bonding and fixing are provided between the surface layer and the middle layer, and between the middle layer and the bottom layer.

[0007] Furthermore, the length of the polytetrafluoroethylene fibers in the surface layer is 6-10 cm, the length of the spandex fibers in the middle layer is 2-5 cm, and the length of the cotton fibers in the bottom layer is 3-4 cm.

[0008] Furthermore, the twist of the polytetrafluoroethylene yarn in the surface layer is 1000-1200 twists / meter, the twist of the spandex yarn in the middle layer is 300-500 twists / meter, and the twist of the cotton yarn in the bottom layer is 400-600 twists / meter.

[0009] A production process for anti-pilling knitted fabric comprises the following process steps: S1, raw material processing, surface treatment of polytetrafluoroethylene fibers, increasing the surface roughness of polytetrafluoroethylene fibers, twisting the surface treated polytetrafluoroethylene fibers into polytetrafluoroethylene yarns, twisting spandex fibers into spandex yarns, twisting cotton fibers into cotton yarns, combing the cotton yarns and adjusting the twist; S2, layered weaving, using a warp knitting machine to weave polytetrafluoroethylene yarn into the fabric surface layer, using a weft knitting machine to weave spandex yarn into the fabric middle layer, and using a single-sided knitting machine to weave cotton yarn into the fabric bottom layer; S3, interlayer bonding, placing a layer of hot melt adhesive film between the woven surface layer and the middle layer, placing a layer of hot melt adhesive film between the woven middle layer and the bottom layer, and pressing the three layers of fabric by a laminating machine; S4, cooling and shaping, the composite fabric after lamination is quickly cooled by a cold press to solidify the hot melt adhesive, and then the composite fabric is heat-shaped; S5, subsequent treatment, shearing or sanding the surface of the composite fabric, and performing antistatic treatment on the composite fabric.

[0010] Furthermore, the surface treatment steps of the polytetrafluoroethylene fiber in step S1 are as follows: S110, preparing materials, placing polytetrafluoroethylene fibers in a processing chamber of a plasma processing device; S120, vacuum pumping, pumping the gas in the processing chamber to a low vacuum state; S130, plasma generation, applying a high frequency voltage or a radio frequency power supply to the processing chamber to generate plasma; S140, surface treatment, plasma reacts with the surface of the polytetrafluoroethylene fiber to remove part of the surface material of the polytetrafluoroethylene fiber; S150, clean up, restore normal pressure and take out the treated polytetrafluoroethylene fiber.

[0011] Furthermore, in step S3, the temperature of the laminating machine is between 100° C. and 120° C., and a pressure of 3-5 MPa is applied to the three layers of fabric for 15-30 seconds.

[0012] Furthermore, the temperature of the heat setting treatment in step S4 is between 150° C. and 170° C., and the heat setting time is 30 to 60 seconds.

[0013] Furthermore, the antistatic treatment step in step S5 is as follows: S510, prepare antistatic agent solution, use modified silicone oil, the concentration of modified silicone oil is 2%-5%; S520, soaking the fabric, completely soaking the composite fabric in the modified silicone oil solution for 5-10 minutes; S530, calendering treatment, using a calender to calender the soaked fabric, the calender temperature is 100-150℃, the pressure is 150-200N / cm², and the calendering time is 8-15 seconds; S540, drying and curing, drying the treated fabric by a hot air blower or a drying machine, the drying temperature is 80-120°C, and the drying time is 10-30 minutes.

[0014] The working principle and beneficial effects of the present invention are: The present invention adopts a three-layer structural design, in which each layer of fibers performs its own function, effectively distributing the functions, so that the overall anti-pilling performance of the fabric is enhanced. Specifically, due to the low friction coefficient and wear resistance of polytetrafluoroethylene fibers, the surface layer is not prone to friction and pilling between fibers; the smooth surface of this material reduces the formation of burrs, fundamentally solving the problem of pilling caused by fiber friction. The high elasticity of spandex fibers helps the fabric to maintain its structural integrity during stretching and movement, reducing friction between internal fibers; this not only enhances the elasticity and durability of the fabric, but also indirectly reduces the risk of pilling. The softness and hygroscopicity of cotton fibers ensure the comfort of the fabric when it comes into contact with the skin. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0016] Figure 1It is a schematic diagram of the structure of the present invention; In the figure: 1, surface layer; 2, middle layer; 3, bottom layer; 4, hot melt adhesive film. DETAILED DESCRIPTION

[0017] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] like Figure 1 As shown, this embodiment proposes an anti-pilling knitted fabric, including an anti-pilling surface layer 1, an intermediate layer 2 for increasing the elasticity and stretchability of the knitted fabric, and a bottom layer 3 for increasing the air permeability and comfort of the knitted fabric. The surface layer 1 is woven from polytetrafluoroethylene fibers twisted into polytetrafluoroethylene yarns, the intermediate layer 2 is woven from spandex fibers twisted into spandex yarns, and the bottom layer 3 is woven from cotton fibers twisted into cotton yarns. The surface layer 1 accounts for 20%-30%, the intermediate layer 2 accounts for 40%-50%, and the bottom layer 3 accounts for 20%-30%. Hot melt adhesive films 4 for bonding and fixing are arranged between the surface layer 1 and the intermediate layer 2, and between the intermediate layer 2 and the bottom layer 3.

[0019] Polytetrafluoroethylene has extremely high wear resistance and tear resistance, is not easily damaged by friction, and has a smooth surface with an extremely low friction coefficient, which is not easy to generate static electricity, thereby reducing the friction between the surface layers 1 of the fabric, thereby significantly reducing the possibility of pilling. The surface layer 1 is made of polytetrafluoroethylene, accounting for 20%-30% to ensure sufficient thickness to resist wear and pilling; this ratio can fully utilize the low friction and wear resistance of polytetrafluoroethylene, and will not make the surface layer 1 too thick to affect the softness and overall feel of the fabric; if the surface layer 1 accounts for less than 20%, the coverage of the polytetrafluoroethylene fiber is insufficient, and it may not be able to effectively exert its anti-pilling function, causing the fabric surface to be easily damaged by friction; if the surface layer 1 accounts for more than 30%, the polytetrafluoroethylene fiber will occupy the main part of the fabric, which may cause the overall fabric to be too rigid, affecting comfort and breathability, and the weight of the fabric may also increase, thereby affecting its softness and wearing experience. Spandex is highly elastic and can be stretched to several times its original length, and can quickly return to its original shape after stretching. Spandex can still maintain good elasticity during repeated stretching and has a very soft feel. It can be mixed with other materials to improve the comfort of the fabric. Spandex as the middle layer 2 can significantly increase the elasticity and stretchability of the knitted fabric, making it more suitable for the application of close-fitting clothing, and it helps the fabric to maintain its shape during use and reduce the friction caused by stretching, thereby indirectly reducing the generation of pilling. The middle layer 2 is made of spandex, accounting for 40%-50%, which ensures that the fabric has good elasticity and stretchability. The high proportion of spandex can provide sufficient stretching space, so that the fabric can quickly return to its original shape when stressed or worn. If the middle layer 2 accounts for less than 40%, the elastic effect of the spandex fiber cannot be fully exerted, and the ductility and resilience of the fabric will be insufficient, affecting the comfort and wearing experience. If the middle layer 2 accounts for more than 50%, the spandex fiber may cause the fabric to be too elastic, thereby affecting the morphological stability of the fabric, and the fabric may lose the necessary support, resulting in excessive deformation when worn. Cotton has good hygroscopicity, which can effectively absorb and release moisture, so that the fabric remains dry when in contact with the skin; the cotton structure is highly breathable, allowing air to circulate freely, improving wearing comfort; the bottom layer 3 is woven from cotton, providing the fabric with good breathability and a comfortable feel, suitable for long-term wear; the natural properties of cotton help reduce the overall static accumulation of the fabric, thereby further reducing the risk of pilling. The bottom layer 3 is made of cotton, accounting for 20%-30%, which can provide a soft touch and good breathability, making the fabric feel comfortable when worn next to the skin, suitable for long-term contact with the skin; if the bottom layer 3 accounts for less than 20%, the comfort and breathability provided by the cotton fiber may be insufficient, affecting the close fit and breathability of the fabric, thereby affecting the wearing experience; if the bottom layer 3 accounts for more than 30%, the softness of the cotton fiber may dominate the overall characteristics of the fabric, causing the fabric to lose structural support and be too soft, thereby affecting its durability and anti-pilling effect.

[0020] Preferably, the surface layer 1 accounts for 25%, the middle layer 2 accounts for 45%, and the bottom layer 3 accounts for 30%. The 25% ratio of the polytetrafluoroethylene fiber surface layer 1 can provide sufficient thickness, make full use of the low friction coefficient and wear resistance of the polytetrafluoroethylene fiber, and ensure that it effectively prevents the generation of pilling in daily use; at the same time, this ratio will not excessively increase the hardness of the fabric, and still maintain the softness and comfort of the fabric, while providing sufficient surface protection to prevent the wear of the fibers of the middle layer 2 and the bottom layer 3. The 45% ratio of the spandex fiber middle layer 2 can provide significant elasticity to the fabric, so that it can quickly recover to its original shape when stretched or compressed. This ratio of spandex fiber helps to reduce the friction between the surface layer 1 and the bottom layer 3, thereby reducing the possibility of pilling, while enhancing the overall durability of the fabric. The 30% ratio of the cotton fiber bottom layer 3 can provide excellent comfort and breathability for the fabric, making the fabric more suitable for long-term contact with the skin, especially during exercise or daily wear, and such a ratio helps to manage moisture and provide a soft touch.

[0021] The hot melt adhesive film 4 is used to bond the surface layer 1, the middle layer 2 and the bottom layer 3 to ensure a firm bond between the layers. The hot melt adhesive film 4 has the characteristics of low temperature melting, fast curing, good bonding strength and flexibility. It can be bonded with a variety of materials and has strong adaptability. It can form a uniform bonding layer during the processing process to ensure a firm connection between the layers.

[0022] In this embodiment, the length of the polytetrafluoroethylene fibers in the surface layer 1 is 6-10 cm, the length of the spandex fibers in the middle layer 2 is 2-5 cm, and the length of the cotton fibers in the bottom layer 3 is 3-4 cm.

[0023] The length of 6-10 cm provides sufficient ductility for the polytetrafluoroethylene fiber, so that it can better cover and protect the surface of the fabric, reduce the chance of friction and wear, and effectively prevent the generation of pilling; and it increases the surface contact area of ​​the yarn, which helps to closely combine the yarns, enhances the overall structural stability of the fabric, and further reduces the possibility of pilling; if the fiber length is less than 6 cm, it is easy to fall off during weaving or cannot form a stable structure, resulting in uneven fabric surface; if the fiber length exceeds 10 cm, it may cause the yarn fibers to loosen, reduce the tightness of the yarn during weaving, and thus affect the anti-pilling effect. The spandex fiber length of 2-5 cm can provide good elasticity for the fabric, and at the same time will not affect the softness and feel of the fabric due to the excessive length of the fiber; and it reduces the degree of interlacing of the fibers in the fabric, thereby reducing the friction between the fibers and further reducing the generation of pilling; if the fiber length is less than 2 cm, it may cause the yarn to be insufficiently elastic, affecting the stretchability and comfort of the middle layer 2; if the fiber length exceeds 5 cm, it may cause the yarn to loosen during weaving, affecting the elasticity and resilience. A cotton fiber length of 3-4 cm helps to form a soft fabric surface, improves the feel and comfort of the fabric, and is suitable for close-fitting wear. If the fiber length is less than 3 cm, it will easily affect the strength of the yarn and the durability of the fabric; if the fiber length exceeds 4 cm, it will easily cause the yarn to be not woven tightly enough, affecting the breathability and softness of the fabric.

[0024] Preferably, the length of the polytetrafluoroethylene fiber is 8 cm, which provides good coverage for the surface layer 1, ensuring that the fibers can form a uniform and tight fabric surface, thereby enhancing the anti-pilling performance. The length of the spandex fiber is 4 cm, which provides sufficient elasticity for the middle layer 2 and ensures that the fibers can be evenly distributed in the yarn, thereby improving the stretchability of the fabric. The length of the cotton fiber is 3.5 cm, which provides good softness and breathability for the bottom layer 3, ensuring that the fabric is close-fitting and comfortable.

[0025] In this embodiment, the twist of the polytetrafluoroethylene yarn in the surface layer 1 is 1000-1200 twists / m, the twist of the spandex yarn in the middle layer 2 is 300-500 twists / m, and the twist of the cotton yarn in the bottom layer 3 is 400-600 twists / m.

[0026] The yarn twist of 1000-1200 twists / m makes the polytetrafluoroethylene yarn tighter and increases the friction between the yarns, thereby enhancing the wear resistance and tear resistance of the yarn and further reducing the risk of pilling; the high-twist polytetrafluoroethylene yarn is more elastic and strong during the stretching process and is not easy to break, which helps to maintain the integrity of the fiber and extend the service life of the fabric; if the yarn twist of the polytetrafluoroethylene yarn is less than 1000 twists / m, the twist is too low, which will make the yarn loose and reduce the anti-pilling effect; if the yarn twist of the polytetrafluoroethylene yarn exceeds 1200 twists / m, the twist is too high, which may cause the yarn to be too hard, affecting the softness and comfort of the fabric. The medium twist of 300-500 twists / m provides sufficient compactness for the spandex fiber without over-compressing the elasticity of the fiber, thereby maintaining the elasticity and comfort of the fabric; the moderate twist enhances the strength of the spandex yarn, reduces the risk of breakage during stretching, and helps to improve the overall durability of the fabric; if the yarn twist of the spandex yarn is less than 300 twists / m, the twist is too low, which will make the yarn loose and reduce the elasticity of the middle layer 2; if the yarn twist of the spandex yarn exceeds 500 twists / m, the twist is too high, which may cause the yarn to lose elasticity, affecting the comfort and resilience of the fabric. A twist of 400-600 twists / m can effectively balance the hygroscopicity and strength of cotton yarn, so that the yarn has a certain softness and breathability while maintaining good durability and structural stability; moderate twist can reduce the accumulation of static electricity between fibers, thereby further reducing the risk of pilling caused by static electricity; if the yarn twist of cotton yarn is less than 400 twists / m, the twist is too low, which will make the yarn loose and affect the durability and surface smoothness of the fabric; if the yarn twist of cotton yarn exceeds 600 twists / m, the twist is too high, which may cause the yarn to be too hard, affecting the softness and comfort of the fabric.

[0027] Preferably, the yarn twist of the polytetrafluoroethylene yarn is 1100 twists / m, which provides good yarn strength and compactness, helps to reduce friction between fibers, and improves durability. The yarn twist of the spandex yarn is 400 twists / m, which provides moderate elasticity and softness for the middle layer 2, ensuring the comfort of the fabric. The yarn twist of the cotton yarn is 500 twists / m, which provides good softness and strength for the bottom layer 3, ensuring the durability and comfort of the fabric.

[0028] A production process for anti-pilling knitted fabric comprises the following process steps: S1. Raw material processing: surface treatment of polytetrafluoroethylene fibers to increase their surface roughness and enhance their bonding strength with other materials; twisting and forming polytetrafluoroethylene yarns on the surface-treated polytetrafluoroethylene fibers; twisting and forming spandex yarns on the spandex fibers; twisting and forming cotton yarns on the cotton fibers; combing and twisting the cotton yarns to ensure that the fibers are uniform and soft, so as to enhance the bonding strength of the cotton with other materials; S2, layered weaving, using a warp knitting machine to weave polytetrafluoroethylene yarn into a flat fabric surface layer 1, the warp knitting process can improve the density and strength of the fabric and reduce the looseness of polytetrafluoroethylene, using a weft knitting machine to weave spandex yarn into an elastic fabric middle layer 2, using a single-sided knitting machine to weave cotton yarn into a soft and breathable fabric bottom layer 3, the bottom layer 3 should be woven with a low yarn twist to ensure the softness and comfort of the fabric; S3, interlayer bonding, placing a layer of hot melt adhesive film 4 between the woven surface layer 1 and the middle layer 2, placing a layer of hot melt adhesive film 4 between the woven middle layer 2 and the bottom layer 3, and pressing the three layers of fabric together with the hot melt adhesive film 4 through a laminating machine to ensure that the adhesive film is completely melted and penetrates between the fibers; S4, cooling and shaping, the composite fabric after lamination is quickly cooled by a cold press to solidify the hot melt adhesive to ensure the structural stability of the composite fabric, and then the composite fabric is heat-shaped to maintain the elasticity and comfort of the fabric; S5, subsequent treatment, the surface of the composite fabric is slightly sheared or sanded to ensure the flatness and feel of the fabric surface layer 1. Shearing can remove excess fibers on the surface and improve the smoothness of the fabric. The composite fabric is then treated with antistatic treatment to reduce static electricity accumulation between polytetrafluoroethylene and cotton and prevent friction pilling.

[0029] In this embodiment, the surface treatment steps of the polytetrafluoroethylene fiber in step S1 are as follows: S101, preparing materials, placing polytetrafluoroethylene fibers in a processing chamber of a plasma processing device; S102, vacuum pumping, pumping the gas in the processing chamber to a low vacuum state to induce a plasma reaction; S103, plasma generation, applying a high frequency voltage or a radio frequency (RF) power supply to the processing chamber to ionize the gas (such as oxygen, nitrogen or air) in the processing chamber to form plasma; S104, surface treatment, plasma reacts with the surface of the polytetrafluoroethylene fiber to remove part of the surface material of the polytetrafluoroethylene fiber and increase the surface roughness and chemical activity; S105, cleaning, restoring normal pressure and taking out the treated polytetrafluoroethylene fiber.

[0030] In this embodiment, the temperature of the laminator in step S3 is between 100°C and 120°C. Within this temperature range, the hot-melt adhesive film 4 will be fully melted and can penetrate well between the fibers to achieve firm bonding of different layers of fabrics. This temperature range is relatively low and will not damage the physical properties of polytetrafluoroethylene, spandex and cotton, thereby ensuring the integrity and functionality of the materials. If the pressing temperature is lower than 100°C, the hot-melt adhesive film 4 may not be fully melted, resulting in poor bonding, which may lead to weak bonding between fabric layers. If the pressing temperature exceeds 120°C, the hot-melt adhesive film 4 may be over-melted, which may cause the glue to penetrate too deeply or cause thermal damage to the fabric, affecting the structure and performance of the fabric. The laminator applies a pressure of 3-5Mpa to the three-layer fabric. Within this pressure range, the hot melt adhesive film 4 can be evenly distributed in a molten state and effectively penetrate between the yarns and fibers to form a strong bond. Within this pressure range, the bonding force between different fabric layers can be enhanced, and the overall strength and durability of the composite material can be improved. If the pressing pressure is lower than 3Mpa, the hot melt adhesive film 4 may not be able to fully contact the fibers, resulting in unsatisfactory bonding effects and affecting the overall quality of the fabric. If the pressing pressure exceeds 5Mpa, the fabric may be over-compressed, affecting the elasticity and comfort of the fabric, and may even cause deformation or damage to the fabric. The laminating machine presses for 15-30 seconds. This time range can ensure that the hot-melt adhesive film 4 has enough time to complete melting and penetration to form a stable bond. At the same time, controlling it within a shorter time range can not only ensure the bonding effect, but also improve the production efficiency, which is suitable for large-scale production; if the pressing time is less than 15 seconds, the hot-melt adhesive film 4 may not be completely melted and penetrated, the bonding effect is poor, and the interlayer fixation of the fabric is not firm; if the pressing time exceeds 30 seconds, the fabric may be heated for too long, causing thermal damage to the fibers or excessive melting of the hot-melt adhesive film 4, affecting the performance of the fabric.

[0031] Preferably, the laminating temperature is 110°C, which is a moderate temperature that can effectively melt the hot melt adhesive film 4 and penetrate between the fabric layers, while avoiding potential damage to the fibers caused by excessively high temperatures. This temperature can ensure good bonding without damaging the fabric. The laminating pressure is 4Mpa, which can ensure that the hot melt adhesive film 4 evenly penetrates between the fabric layers to form a strong bond without causing excessive compression or damage to the fabric. The laminating time is 20 seconds, which can ensure that the hot melt adhesive film 4 is fully melted and well bonded to the fiber layer, while avoiding excessive heat effects on the fabric due to too long a time.

[0032] In this embodiment, the temperature of the heat setting treatment in step S4 is between 150°C and 170°C. Within this temperature range, heat setting the composite fabric can fix the shape of the fabric and prevent the fabric from shrinking, deforming and other problems in subsequent use. In addition, the spandex and cotton within this temperature range can maintain the elasticity and softness of the fibers, ensuring the comfort and durability of the fabric during use. If the heat setting temperature is lower than 150°C, it may result in poor heat setting effect and inability to effectively maintain the elasticity and stability of the fabric. If the heat setting temperature exceeds 170°C, it may result in excessive heat treatment of the fibers, impairing the elasticity and feel of the fabric, and may even cause thermal damage. The heat setting time is 30-60 seconds. This time range can ensure that each layer of the fabric fully releases internal stress during the heat setting process and achieves a stable shape, thereby ensuring that the elasticity of the spandex is preserved while ensuring the comfort of the cotton. If the heat setting time is less than 30 seconds, the heat setting effect may be insufficient, and the elasticity and comfort of the fabric cannot be fully exerted. If the heat setting time exceeds 60 seconds, the fiber may be over-processed, and the fabric may become over-hardened or its performance may deteriorate.

[0033] Preferably, the heat setting temperature is 160°C, which can effectively heat set spandex and cotton fibers, maintain the elasticity and comfort of the fabric, and avoid potential damage to the fabric caused by excessive temperature. The heat setting time is 45 seconds, which can ensure that the heat setting process is sufficient, ensure that spandex and cotton fibers have a good setting effect, and thus improve the elasticity and comfort of the fabric.

[0034] In this embodiment, the antistatic treatment steps in the subsequent treatment are as follows: S501, prepare antistatic agent solution, use modified silicone oil, the concentration of modified silicone oil is 2%-5%; S502, soaking the fabric, completely soaking the composite fabric in the modified silicone oil solution, the modified silicone oil can evenly cover the fiber surface, making the fabric feel softer and smoother, while enhancing the anti-pilling performance of the fabric, the soaking time is 5-10 minutes, during the soaking process, it can be gently stirred to ensure uniform treatment; S503, calendering treatment, use a calender to calender the soaked fabric. Calendering treatment can effectively smooth the fabric surface, reduce the protrusions and burrs between fibers, and further reduce the probability of pilling. Calendering treatment can also help to solidify the modified silicone oil to a certain extent, making it more firmly attached to the fiber surface and improving the durability of the fabric. The calender temperature is 100-150℃, the pressure is 150-200N / cm², and the calendering time is 8-15 seconds; S504, drying and curing, drying the treated fabric by a hot air blower or a drying machine, the drying temperature is 80-120°C, and the drying time is 10-30 minutes.

[0035] Compared with the modified silicone oil concentration range of 2%-5%, if the modified silicone oil concentration is lower than 2%, the effect of silicone oil may be insufficient, it is difficult to effectively cover the fiber surface, and the expected anti-pilling effect cannot be achieved, and the softness and durability of the fabric will also be affected; if the modified silicone oil concentration exceeds 5%, the fabric surface may be too slippery, affecting the feel and breathability of the fabric, and may cause excessive accumulation of silicone oil, affecting the subsequent process treatment effect. Compared with the immersion time range of 5-10 minutes, if the immersion time is less than 5 minutes, the treatment agent cannot fully penetrate, the anti-pilling effect may not be as expected, affecting the performance and quality of the product; if the immersion time exceeds 10 minutes, the fabric may absorb too much treatment agent, which in turn affects the hardness and elasticity of the fabric, and may increase the uncertainty in the subsequent treatment process.

[0036] Preferably, the modified silicone oil concentration is 3%. A modified silicone oil concentration of 3% can provide good softness and anti-pilling performance without affecting the feel of the fabric. This concentration balances the distribution and penetration of silicone oil, allowing it to evenly cover the fiber surface, thereby improving the durability of the fabric. The soaking time is 8 minutes, which is enough to allow the modified silicone oil to evenly penetrate into the internal fiber structure of the fabric, ensuring uniform treatment and enhancing the anti-pilling effect, while avoiding excessive absorption that causes the fiber to soften too much.

[0037] Relative to the calender temperature range of 100-150℃, if the calender temperature is lower than 100℃, the modified silicone oil may not be fully softened, affecting its uniform distribution and adhesion effect, thereby reducing the anti-pilling performance; if the calender temperature exceeds 150℃, the fiber structure may be damaged, especially for fiber materials with strong heat sensitivity, the fiber may melt or the strength may decrease. Relative to the calender pressure range of 150-200N / cm², if the pressure is lower than 150 N / cm², the modified silicone oil may not fully penetrate, affecting its distribution effect in the fabric and reducing the anti-pilling performance; if the pressure exceeds 200N / cm², the fabric will be over-compressed, which may destroy the elasticity and comfort of the fabric, and may cause uneven gloss on the fabric surface or structural deformation. Compared with the calendering time range of 8-15 seconds, if the calendering time is less than 8 seconds, the penetration and curing of the modified silicone oil cannot be fully completed, which may lead to unsatisfactory anti-pilling effect and affect the final quality of the product; if the calendering time exceeds 15 seconds, it may cause excessive compression and deformation of the fiber, affecting the elasticity and comfort of the fabric, and may cause permanent indentation.

[0038] Preferably, the calender temperature is 130°C. The temperature of 130°C can effectively soften and evenly distribute the modified silicone oil, so that it can better adhere to the fiber surface and improve the stability and anti-pilling performance of the fiber. This temperature can achieve the effect without damaging the fiber structure. The calender pressure is 200 N / cm². The pressure of 200 N / cm² can ensure that the modified silicone oil penetrates evenly into each layer of the fabric, while ensuring close contact between the fibers, enhancing the stability and anti-pilling effect of the fabric. The calender time is 12 seconds. The calender time of 12 seconds can give full play to the role of the modified silicone oil without damaging the fiber, ensuring that it is evenly distributed on the fabric surface, thereby achieving an ideal anti-pilling effect.

[0039] Relative to the drying temperature range of 80-120℃, if the drying temperature is lower than 80℃, the water may not be effectively evaporated, resulting in too high moisture content of the fabric, affecting the effect of subsequent processes and anti-pilling performance; if the drying temperature exceeds 120℃, the fiber may be over-dried or even thermally damaged, affecting the physical properties of the fiber and the overall quality of the fabric. Relative to the drying time range of 10-30 minutes, if the drying time is less than 10 minutes, the moisture content of the fabric may be too high, the modified silicone oil may not be fully cured, and its anti-pilling effect may be affected; if the drying time exceeds 30 minutes, the fabric may be over-dried, affecting the softness and elasticity of the fabric, and may also cause static electricity problems.

[0040] Preferably, the drying temperature is 100°C, which is sufficient to evaporate excess moisture on the fiber without damaging the fiber structure, ensuring that the fabric maintains good elasticity and softness. The drying time is 20 minutes, which can fully remove moisture from the fabric at an appropriate temperature, ensuring that the modified silicone oil is solidified on the fiber surface, and enhancing the anti-pilling effect.

[0041] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A pilling-resistant knitted fabric, characterized in that: The invention comprises an anti-pilling surface layer (1), an intermediate layer (2) for increasing the elasticity and stretchability of the knitted fabric, and a bottom layer (3) for increasing the air permeability and comfort of the knitted fabric. The surface layer (1) is woven from polytetrafluoroethylene fibers twisted into polytetrafluoroethylene yarns, the intermediate layer (2) is woven from spandex fibers twisted into spandex yarns, and the bottom layer (3) is woven from cotton fibers twisted into cotton yarns. The surface layer (1) accounts for 20%-30%, the intermediate layer (2) accounts for 40%-50%, and the bottom layer (3) accounts for 20%-30%. Hot melt adhesive films (4) for bonding and fixing are provided between the surface layer (1) and the intermediate layer (2), and between the intermediate layer (2) and the bottom layer (3).

2. The anti-pilling knitted fabric according to claim 1, characterized in that: The length of the polytetrafluoroethylene fibers in the surface layer (1) is 6-10 cm, the length of the spandex fibers in the middle layer (2) is 2-5 cm, and the length of the cotton fibers in the bottom layer (3) is 3-4 cm.

3. The anti-pilling knitted fabric according to claim 1, characterized in that: The twist of the polytetrafluoroethylene yarn in the surface layer (1) is 1000-1200 twists / meter, the twist of the spandex yarn in the middle layer (2) is 300-500 twists / meter, and the twist of the cotton yarn in the bottom layer (3) is 400-600 twists / meter.

4. A process for producing an anti-pilling knitted fabric according to any one of claims 1 to 3, characterized in that: The process steps include: S1, raw material processing, surface treatment of polytetrafluoroethylene fibers, increasing the surface roughness of polytetrafluoroethylene fibers, twisting the surface treated polytetrafluoroethylene fibers into polytetrafluoroethylene yarns, twisting spandex fibers into spandex yarns, twisting cotton fibers into cotton yarns, combing the cotton yarns and adjusting the twist; S2, layered weaving, using a warp knitting machine to weave polytetrafluoroethylene yarn into a fabric surface layer (1), using a weft knitting machine to weave spandex yarn into a fabric middle layer (2), and using a single-knitting machine to weave cotton yarn into a fabric bottom layer (3); S3, interlayer bonding, placing a layer of hot melt adhesive film (4) between the woven surface layer (1) and the middle layer (2), placing a layer of hot melt adhesive film (4) between the woven middle layer (2) and the bottom layer (3), and pressing the three layers of fabric together using a laminating machine; S4, cooling and shaping, the composite fabric after lamination is quickly cooled by a cold press to solidify the hot melt adhesive, and then the composite fabric is heat-shaped; S5, subsequent treatment, shearing or sanding the surface of the composite fabric, and performing antistatic treatment on the composite fabric.

5. The production process of an anti-pilling knitted fabric according to claim 4, characterized in that: The steps of surface treatment of polytetrafluoroethylene fiber in step S1 are as follows: S110, preparing materials, placing polytetrafluoroethylene fibers in a processing chamber of a plasma processing device; S120, vacuum pumping, pumping the gas in the processing chamber to a low vacuum state; S130, plasma generation, applying a high frequency voltage or a radio frequency power supply to the processing chamber to generate plasma; S140, surface treatment, plasma reacts with the surface of the polytetrafluoroethylene fiber to remove part of the surface material of the polytetrafluoroethylene fiber; S150, clean up, restore normal pressure and take out the treated polytetrafluoroethylene fiber.

6. The production process of an anti-pilling knitted fabric according to claim 4, characterized in that: In step S3, the temperature of the laminating machine is between 100° C. and 120° C., and a pressure of 3-5 MPa is applied to the three layers of fabric for 15-30 seconds.

7. The production process of an anti-pilling knitted fabric according to claim 4, characterized in that: The temperature of the heat setting treatment in step S4 is between 150° C. and 170° C., and the heat setting time is 30 to 60 seconds.

8. The production process of an anti-pilling knitted fabric according to claim 4, characterized in that: The antistatic treatment steps in step S5 are as follows: S510, prepare antistatic agent solution, use modified silicone oil, the concentration of modified silicone oil is 2%-5%; S520, soaking the fabric, completely soaking the composite fabric in the modified silicone oil solution for 5-10 minutes; S530, calendering treatment, using a calender to calender the soaked fabric, the calender temperature is 100-150℃, the pressure is 150-200N / cm², and the calendering time is 8-15 seconds; S540, drying and curing, drying the treated fabric by a hot air blower or a drying machine, the drying temperature is 80-120°C, and the drying time is 10-30 minutes.

Images