Flexible production method of first-weaving and second-dyeing tapestry satin

Abstract

The invention relates to the technical field of brocade satin production, in particular to a first-weaving second-dyeing flexible production method for brocade satin, which comprises the following production steps: S1, a processing workshop order group distributes tasks to a raw material preparation group, a weaving group, a dyeing group, a sewing group and an arrangement and quality inspection group in advance according to the order quantity of the day; s2, the raw material preparation group prepares raw material treatment, the raw materials are subjected to cutting, bleaching and dipping treatment, a neutral detergent is prepared, the wire is put into the neutral detergent to be soaked, and the performance of the wire is improved. The assembly lines in the workshop are divided into a plurality of groups, the groups correspond to different machining production processes, a long assembly line is shortened to be a short assembly line for 3-10 persons, segmented unit operation is achieved, the production processes and resource allocation can be rapidly adjusted according to changes of markets and orders to adapt to different requirements and changes, and the production efficiency is improved. And a better use prospect is brought.

Description

Technical Field

[0001] The invention belongs to the technical field of brocade production, and in particular relates to a flexible production method of brocade by first weaving and then dyeing. Background Art

[0002] Brocade is the most famous traditional silk fabric in China. It is also the most exquisite and gorgeous triple weft fabric among silk fabrics. The fabric of brocade is a single-color warp satin material with at least 3 kinds of colored silk as the weft satin pattern. Twill is also used as auxiliary decoration during production. It is one of the traditional silk varieties in my country. Brocade was developed on the basis of Jiangnan brocade in my country at the end of the 19th century. It is based on satin pattern and more than three kinds of colored silk as the weft, that is, a triple weft fabric with one group of warp and three groups of weft interwoven. Eight warp satin patterns are woven on jacquard machines. Modern brocade is made according to the original The material can be divided into nine categories: pure silk brocade, rayon brocade, interwoven brocade and gold and silver brocade. It has exquisite patterns, brilliant colors, tight and thick texture, smooth and shiny surface. It is a representative variety of silk in my country. When processing brocade on the market, it is often produced on an assembly line. During processing, the production line is only one, and the production process and resource allocation cannot be quickly adjusted according to changes in the market and orders, and it cannot adapt to different needs and changes. In this regard, we proposed a flexible production method for brocade that weaves first and then dyes. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention provides a flexible production method for brocade by weaving first and then dyeing to solve the above technical problems.

[0004] To achieve the above object, the present invention provides the following technical solution: a method for producing a flexible brocade by weaving first and then dyeing, the production steps being:

[0005] S1. The order group of the processing workshop allocates tasks to the raw material preparation group, weaving group, dyeing group, sewing group and finishing quality inspection group in advance according to the order volume of the day;

[0006] S2. The raw material preparation group prepares the raw materials, performs cutting, bleaching and dipping treatment on the raw materials, prepares a neutral detergent, soaks the silk material in the neutral detergent to improve the performance of the silk material, takes out the silk thread after soaking, sprays aloe essential oil on the outer surface of the silk thread, and air-dries it;

[0007] S3, the weaving group weaves the treated material, draws the warp and weft threads, combs the horns, and winds the weft threads to make fabrics to become grey silk;

[0008] S4, the dyeing group dyes the prepared grey silk, soaks the grey silk in water in advance to fully absorb water and expand the fibers, takes out the grey silk, folds it into a bundle, and immerses it in a dye solution for dyeing;

[0009] S5, the sewing group sews the grey silk to fix the warp and weft threads to form a complete fabric by using a special sewing machine;

[0010] S6, the finishing quality inspection team finishes the sewn brocade and checks whether there are defects in the production of the brocade, and screens out the products with defects;

[0011] S7. If there are changes in the orders of the processing workshop order group on the same day, the products produced by each group will be used as backup for the production of subsequent orders.

[0012] Preferably, in step S1, the assembly lines in the current processing workshop are divided into a processing workshop order group, a raw material preparation group, a weaving group, a dyeing group, a sewing group and a finishing and quality inspection group, wherein the processing workshop order group is used to organize and collect processing orders, make statistical arrangements, and arrange the workshop assembly line group for production and processing.

[0013] Preferably, the raw materials in step S2 include gold and silver threads, silk and nylon, and the bleaching step prepares a bleaching solution, bleaching the prepared silk threads, soaking them for 12 hours, then taking them out and rinsing them with clean water; the soaking time is 6 hours, and aloe vera essential oil is manually sprayed onto the outer surface of the silk threads through a spray pot.

[0014] Preferably, in step S3, the silk is drawn by pulling the silk threads onto a silk drawing frame and combing them to make the intervals between them equal; the sheep's horns are combed by winding the combed silk threads onto the horizontal column in the middle of the sheep's horns, and white cotton threads are wound on it. An equal width distance corresponding to the number of silks drawn must be left between the cotton threads, and the subsequent cotton threads are wound in the same way. Each circle of winding corresponds to the odd and even number of cotton loops on the first wooden stick, and the circles are linked together. The weft winding weft threads are interwoven on the warp threads, overlapping each other to form the raw silk.

[0015] Preferably, in step S4, white silk is placed in the prepared water, and then continuously turned over to allow the silk to fully absorb water. The turning time is 2 hours. In the dyeing step, different dyes are prepared in advance to mix the colors. The dyes are pure natural plant dyes. The plant dyes include woad, madder, gardenia, frozen green, comfrey, yam, gallnut, tannin, locust flower and onion peel. Dyes of different colors are prepared by extracting pigments from these plants.

[0016] Preferably, the dyeing step also involves airing the soaked grey silk in the sun for 6 hours, folding the dried grey silk into strips, slowly immersing it in the dyeing solution, and constantly stirring it so that the dyeing solution is evenly absorbed by the grey silk. After taking it out, it is dried and the color is allowed to stabilize.

[0017] Preferably, the sewing step in step S5 is to cut the grey silk into the size required by the order, and weave colored silk on the outer surface, that is, one set of warp and three sets of weft are interwoven to form a triple-grain fabric, and the stitches are ensured to be uniform during sewing. After sewing, the brocade is sorted and the excess sewing threads are cut off; after cutting, the brocade is ironed to keep it flat.

[0018] Preferably, the method for inspecting brocade satin in step S6 combines appearance quality inspection with internal quality inspection, and the quality inspection team inspects the produced brocade satin through visual observation, and the judgment is based on whether there are defects on the outer surface, whether the color and pattern are correct, and whether the warp and weft are broken.

[0019] Firstly, the finishing quality inspection team will conduct a touch inspection on the brocade by pulling it to check the density, strength and wrinkle resistance of the brocade to see if it meets the production standards.

[0020] Preferably, in step S7, each group produces in a quantitative manner according to the daily quantity. If there is a change in the order, the excess material is placed in the storage room for storage and collection, waiting for subsequent use.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] The present invention divides the assembly line in the workshop into several groups, each of which corresponds to a different processing and production process, and shortens the long assembly line to a short assembly line with 5-15 people, thereby realizing segmented unit operation. The production process and resource allocation can be quickly adjusted according to changes in the market and orders to adapt to different needs and changes, bringing better usage prospects.

[0023] When producing brocade satin, the present invention divides different production steps into several groups, and in the process of preparing silk threads, the silk threads are soaked in a neutral detergent to improve the silk thread properties, and aloe essential oil is sprayed on the outer surface of the silk threads, and the threads are aired to improve the skin-fitting properties of the prepared brocade satin. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A flow chart was prepared for the present invention. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in 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.

[0026] The present invention provides a technical solution: a flexible production method for brocade by weaving first and then dyeing, the production steps are:

[0027] S1. The order group of the processing workshop allocates tasks to the raw material preparation group, weaving group, dyeing group, sewing group and finishing quality inspection group in advance according to the order volume of the day;

[0028] S2. The raw material preparation group prepares the raw materials, performs cutting, bleaching and dipping treatment on the raw materials, prepares a neutral detergent, soaks the silk material in the neutral detergent to improve the performance of the silk material, takes out the silk thread after soaking, sprays aloe essential oil on the outer surface of the silk thread, and air-dries it;

[0029] S3, the weaving group weaves the treated material, draws the warp and weft threads, combs the horns, and winds the weft threads to make fabrics to become grey silk;

[0030] S4, the dyeing group dyes the prepared grey silk, soaks the grey silk in water in advance to fully absorb water and expand the fibers, takes out the grey silk, folds it into a bundle, and immerses it in a dye solution for dyeing;

[0031] S5, the sewing group sews the grey silk to fix the warp and weft threads to form a complete fabric by using a special sewing machine;

[0032] S6, the finishing quality inspection team finishes the sewn brocade and checks whether there are defects in the production of the brocade, and screens out the products with defects;

[0033] S7. If there are changes in the orders of the processing workshop order group on the same day, the products produced by each group will be used as backup for the production of subsequent orders.

[0034] Furthermore, in step S1, the assembly lines in the current processing workshop are divided into a processing workshop order group, a raw material preparation group, a weaving group, a dyeing group, a sewing group, and a finishing and quality inspection group. The processing workshop order group is used to sort out and collect the processing orders, make statistics, and arrange the workshop assembly line group to carry out production and processing;

[0035] Several groups are divided into groups of 5 to 15 people to handle and process the different production steps of brocade separately.

[0036] Furthermore, in step S2, the raw materials include gold and silver threads, silk and nylon, and the bleaching step prepares a bleaching solution, bleaching the prepared silk thread, soaking it for 12 hours, taking it out and rinsing it with clean water; the soaking time is 6 hours, and the aloe essential oil is manually sprayed onto the outer surface of the silk thread through a spray pot;

[0037] The aloe vera is one or more of arborescent aloe, Cape aloe, everbright city aloe, saponin aloe and Chinese aloe. The preparation steps of the aloe essential oil include:

[0038] Choose mature aloe vera, cut off its leaves, peel off the outer surface, and wash it clean to remove impurities and dust;

[0039] Put the aloe leaves into the crusher and crush them into a viscous liquid;

[0040] Put the crushed aloe vera liquid into an extraction tank, add ethanol, and stir to extract;

[0041] The extracted solution is placed on filter paper for filtering to filter out residues and impurities, and the filtered solution is placed in an evaporation tank for evaporation to remove organic solvents and retain essential oils, thereby completing the extraction of aloe essential oil. The aloe essential oil is poured into a spray pot for later use.

[0042] Furthermore, in step S3, the silk is drawn by pulling the silk threads onto a silk drawing frame and combing them to make the intervals between them equal; the sheep's horns are combed by winding the combed silk threads onto the horizontal column in the middle of the sheep's horns, and white cotton threads are wound on them. An equal width distance corresponding to the number of silks drawn must be left between the cotton threads, and subsequent cotton threads are wound in the same way. Each circle of winding corresponds to the odd and even number of cotton loops on the first wooden stick, and the circles are linked together. The weft winding weft threads are interwoven on the warp threads, overlapping each other to form the raw silk.

[0043] Furthermore, in step S4, the white silk is placed in the prepared water, and then continuously turned over to allow the silk to fully absorb water. The turning time is 2 hours. In the dyeing step, different dyes are prepared in advance to mix the colors. The dyes are pure natural plant dyes. The plant dyes include woad, madder, gardenia, frozen green, comfrey, yam, gallnut, tannin, locust flower and onion skin. Dyes of different colors are prepared by extracting pigments from these plants.

[0044] Furthermore, the dyeing step includes airing the soaked grey silk in the sun for 6 hours, folding the dried grey silk into strips, slowly immersing it in the dyeing solution, and constantly stirring it so that the dyeing solution is evenly absorbed by the grey silk. After taking it out, it is dried and waits for the color to stabilize.

[0045] Furthermore, in step S5, the sewing step is to cut the raw silk into the size required by the order, weave colored silk on the outer surface, that is, interweave one set of warp with three sets of weft to form a triple-grain fabric, ensure that the stitches are even during sewing, and after sewing, trim the brocade and cut off the excess sewing thread ends; after cutting, iron the brocade to keep it flat;

[0046] The steps for ironing brocade are:

[0047] Prepare ironing tools such as iron and towel, put the wet towel under the iron to stimulate moisture and release small water vapor to the outside;

[0048] Choose the appropriate temperature. Different temperatures should be selected for different types of brocade.

[0049] Turn the brocade from the center and place it naturally, iron it with a low-temperature iron, cover it with a wet paper towel, and iron it flat to eliminate wrinkles and creases;

[0050] During the sewing process, choose appropriate stitches and threads to avoid exposed thread ends or broken stitches. At the same time, pay special attention to some details, such as corners and lace, to ensure the overall beauty.

[0051] Furthermore, in step S6, the method for inspecting brocade satin combines appearance quality inspection with internal quality inspection. The quality inspection team inspects the produced brocade satin through visual observation. The judgment is based on whether there are defects on the outer surface, whether the color and pattern are correct, and whether the warp and weft are broken.

[0052] Furthermore, the finishing quality inspection team will conduct a touch inspection on the brocade by pulling it to check its density, strength and wrinkle resistance to see if it meets the production standards.

[0053] Brocade can also be tested by mechanical stretching. During the test, the brocade sample is fixed on a tensile testing machine and the tensile load is gradually increased until the sample breaks. The unit of tensile strength is usually Newton N or Meganewton MN. Based on the test results, the quality and performance of the brocade can be evaluated, as well as the limitations it may face during processing and use.

[0054] Furthermore, in step S7, each group produces in a fixed quantity according to the daily quantity. If there is a change in the order, the excess materials are placed in the storage room for storage and collection, waiting for subsequent use;

[0055] Compared with the traditional assembly line production method, if there is a change in the order of the day, the assembly line production cannot be stopped and can only continue to produce according to the target, then there will be a situation of overproduction, and the excess woven silk cannot be recycled, resulting in waste. The present invention divides the assembly line in the workshop into several groups, and the several groups correspond to different processing and production processes. The long assembly line is shortened to a short assembly line of 5-15 people, and segmented unit operations are realized. The production process and resource allocation can be quickly adjusted according to changes in the market and orders to adapt to different needs and changes, and prevent excess production waste.

[0056] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0057] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for producing flexible brocade by weaving first and then dyeing, characterized in that: The production steps are: S1. The order group of the processing workshop allocates tasks to the raw material preparation group, weaving group, dyeing group, sewing group and finishing quality inspection group in advance according to the order volume of the day; S2. The raw material preparation group prepares the raw materials, performs cutting, bleaching and dipping treatment on the raw materials, prepares a neutral detergent, soaks the silk material in the neutral detergent to improve the performance of the silk material, takes out the silk thread after soaking, sprays aloe essential oil on the outer surface of the silk thread, and air-dries it; S3, the weaving group weaves the treated material, draws the warp and weft threads, combs the horns, and winds the weft threads to make fabrics to become grey silk; S4, the dyeing group dyes the prepared grey silk, soaks the grey silk in water in advance to fully absorb water and expand the fibers, takes out the grey silk, folds it into a bundle, and immerses it in a dye solution for dyeing; S5, the sewing group sews the grey silk to fix the warp and weft threads to form a complete fabric by using a special sewing machine; S6, the finishing quality inspection team finishes the sewn brocade and checks whether there are defects in the production of the brocade, and screens out the products with defects; S7. If there are changes in the orders of the processing workshop order group on the same day, the products produced by each group will be used as backup for the production of subsequent orders.

2. The method for producing brocade flexible fabric by weaving first and then dyeing according to claim 1, characterized in that: In step S1, the assembly lines in the current processing workshop are divided into a processing workshop order group, a raw material preparation group, a weaving group, a dyeing group, a sewing group, and a finishing and quality inspection group. The processing workshop order group is used to organize and collect processing orders, make statistical arrangements, and arrange the workshop assembly line group for production and processing.

3. The method for producing brocade silk by weaving first and then dyeing according to claim 1, characterized in that: The raw materials in step S2 include gold and silver threads, silk and nylon. The bleaching step is to prepare a bleaching solution, bleach the prepared silk threads, soak them for 12 hours, take them out and rinse them with clean water; the soaking time is 6 hours, and aloe vera essential oil is manually sprayed onto the outer surface of the silk threads through a spray pot.

4. The method for producing brocade silk by weaving first and then dyeing according to claim 1, characterized in that: In step S3, the silk is drawn by pulling the silk threads onto the drawing frame and combing them to make the intervals between them equal; the sheep's horn is combed by winding the combed silk threads onto the horizontal column in the middle of the sheep's horn, and then winding white cotton threads on it. An equal width distance corresponding to the number of silks to be drawn must be left between the cotton threads, and the subsequent cotton threads are wound in the same way. Each circle of winding corresponds to the odd and even number of cotton loops on the first wooden stick, and the circles are linked together. The weft winding weft threads are interwoven on the warp threads, overlapping each other to form the raw silk.

5. The method for producing brocade flexible fabric by weaving first and then dyeing according to claim 1, characterized in that: In step S4, white silk is placed in the prepared water, and then continuously turned over to allow the silk to fully absorb water. The turning time is 2 hours. In the dyeing step, different dyes are prepared in advance to mix colors. The dyes are pure natural plant dyes. The plant dyes include woad, madder, gardenia, frozen green, comfrey, yam, gallnut, tannin, locust flower and onion skin. Dyes of different colors are prepared by extracting pigments from these plants.

6. The method for producing brocade flexible fabric by weaving first and then dyeing according to claim 5, characterized in that: The dyeing step also involves airing the soaked grey silk in the sun for 6 hours, folding the dried grey silk into strips, slowly immersing it in the dye solution, and constantly stirring it so that the dye solution is evenly absorbed by the grey silk. After taking it out, it is dried and waits for the color to stabilize.

7. The method for producing brocade silk by weaving first and then dyeing according to claim 1, characterized in that: The sewing step in step S5 is to cut the raw silk into the size required by the order, and weave colored silk on the outer surface, that is, one set of warp and three sets of weft are interwoven to form a triple-grain fabric. The stitches are ensured to be even during sewing. After sewing, the brocade is sorted and the excess sewing threads are cut off. After cutting, the brocade is ironed to keep it flat.

8. The method for producing brocade silk by weaving first and then dyeing according to claim 1, characterized in that: The method for inspecting brocade in step S6 combines appearance quality inspection with internal quality inspection. The quality inspection team inspects the produced brocade by visual inspection. The judgment is based on whether there are defects on the outer surface, whether the color and pattern are correct, and whether the warp and weft are broken.

9. The method for producing brocade silk by weaving first and then dyeing according to claim 8, characterized in that: The finishing quality inspection team then conducts a touch inspection on the brocade satin, pulling it to check its density, strength and wrinkle resistance to see whether it meets the production standards.

10. The method for producing brocade silk by weaving first and then dyeing according to claim 1, characterized in that: In step S7, each group produces according to the daily quantity. If there is a change in the order, the excess materials are placed in the storage room for storage and collection, waiting for subsequent use.

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