Self-adjusting fabric and method for preparing same

Abstract

The present invention provides a self-adjusting fabric and a preparation method thereof. The self-adjusting fabric includes a double-layer structure area arranged diagonally, a single-layer structure area arranged diagonally, and a broken-point filling weft yarn arranged in the foregoing structure areas. The broken-point filling weft yarn includes staple roving, a water-soluble vinylon filament continuously wrapped around the staple roving, and a polyester filament intermittently wrapped around the staple roving, so as to form a first yarn segment without polyester filaments and a second yarn segment with polyester filaments that are alternately distributed. The first yarn segment is arranged between double-layer tissues. During dyeing and processing, the broken-point filling weft yarn in the double-layer structure area untwists and disperses and then fills the double-layer structure area, so that the structure area bulges; due to the wrapping effect of the polyester filaments, the broken-point filling weft yarn in the single-layer structure area continues to interweave in the single-layer structure area in the form of a yarn, and a self-adjusting fabric with a single-double-layer concave-convex structure is obtained. By selecting broken-point filling weft yarns with different functional characteristics, fabrics with different functions can be prepared.

Description

Technical Field

[0001] The present invention relates to the field of textiles, and particularly to a fabric whose fabric structure can be self-adjusted and a preparation method of the self-adjusted fabric. Background Art

[0002] In the prior art, in order to improve the texture of fabrics, double-layer fabrics are increasingly used. In order to further improve the thickness of fabrics, in the prior art, weft insertion yarns are usually introduced between the double-layer tissues of the fabric to make the texture of the fabric rich and thick. However, directly introducing weft insertion yarns between double-layer tissues has the following defects: 1) The process of directly introducing weft insertion yarns limits the selection of the materials of the weft insertion yarns, and fibers with excellent functionality but low spinnability cannot be used, restricting its scope of use; 2) The weft insertion yarns padded between double-layer tissues exist in the form of yarns, and their effect on improving the thickness and three-dimensional sense of the fabric is limited.

[0003] The invention patent with the application number CN201710078665.8 discloses a preparation process of a unidirectional moisture-conducting lightweight warm woven double-layer fabric, and a double-layer structured woven fabric is prepared. Among them, the warp yarns are interwoven with the surface weft through the "inner warp interlacing" method. The surface layer adopts one of polyester profiled-section water-absorbing fibers or cool silk cotton fibers, and the inner layer selects polypropylene hollow fiber colored yarns. One side of the fabric is hydrophobic and moisture-conducting, and the other side is water-absorbing and moisture-discharging, so that the fabric obtains the function of unidirectional moisture conduction.

[0004] The invention patent with the application number CN201810278993.7 discloses a pure cotton bedding fabric with single and double-layer tissues and its manufacturing method. The fabric is formed by interweaving warp yarns and weft yarns according to the tissue structure. The tissue structure includes a single-layer tissue area and a double-layer tissue area. The adjacent double-layer tissue areas are connected by a single-layer tissue area, and the density of the single-layer tissue area is the same as that of the double-layer tissue area; in the minimum tissue repeat of the fabric, the number of interweavings of a single weft yarn with all warp yarns is the same. Its manufacturing method includes a weaving process and a dyeing and finishing process. The fabric of the present invention combines single-layer tissue and double-layer tissue, improves the structural stability of the double-layer fabric, and ensures the consistency of the style before and after washing.

[0005] Although the fabrics prepared by the above methods all adopt double-layer tissue structures and select yarns with specific functions and specific structures to prepare functional textiles, due to the limitations of the double-layer fabric structure and the functional limitations of the selected yarns, the functional improvement of the prepared textiles is limited, and the functional yarns used are exposed outside. The functional yarns are prone to wear and failure and are not resistant to washing, so their service life is not long. Summary of the Invention

[0006] Aiming at the above deficiencies, the purpose of the present invention is to provide a self-adjusted fabric and its preparation method.

[0007] In order to achieve the above-mentioned invention purpose, the present invention provides a self-adjusting fabric, which comprises a plurality of repeating units arranged in an array structure; a single repeating unit includes a first structural area and a fourth structural area arranged diagonally, a second structural area and a third structural area arranged diagonally, and a broken-point filling weft yarn arranged in the foregoing structural areas; the broken-point filling weft yarn includes staple roving, a water-soluble vinylon filament continuously wrapped around the staple roving, and a polyester filament intermittently wrapped around the staple roving, so as to form alternately distributed first yarn segments and second yarn segments;

[0008] The first structural area and the fourth structural area are double-layer tissues composed of a surface tissue and a lining tissue, forming a double-layer structural area, and the first yarn segments of the broken-point filling weft yarn are correspondingly arranged between the surface tissue and the lining tissue, and the first yarn segments are composed of staple roving and a water-soluble vinylon filament wrapped around the staple roving; and in the first structural area, the length of the first yarn segment is consistent with the width of the first structural area along the weft direction; in the fourth structural area, the length of the first yarn segment is consistent with the width of the fourth structural area along the weft direction;

[0009] The second structural area and the third structural area are single-layer tissues, forming a single-layer structural area; the second yarn segments include staple roving, a water-soluble vinylon filament continuously wrapped around the staple roving, and a polyester filament continuously wrapped around the staple roving; and in the second structural area, the length of the second yarn segment is consistent with the width of the second structural area along the weft direction; in the third structural area, the length of the second yarn segment is consistent with the width of the third structural area along the weft direction;

[0010] During the dyeing process, the first yarn segments of the broken-point filling weft yarn in the first structural area and the fourth structural area are untwisted and uniformly dispersed and then filled in the double-layer structural area, so that the double-layer structural area bulges; due to the wrapping effect of the polyester filaments, the second yarn segments of the broken-point filling weft yarn in the second structural area and the third structural area continue to be interwoven in the single-layer structural area in the form of yarns, and a self-adjusting fabric with a single and double-layer concave-convex structure is obtained.

[0011] As a further improvement of the present invention, in the weft direction, the widths of the first structural area and the third structural area are equal, and the widths of the second structural area and the fourth structural area are equal; and the width W A of the first structural area and the width W B of the second structural area satisfy the relational expression: W A :W B <1, so as to form a structure with a convex middle and a concave periphery.

[0012] As a further improvement of the present invention, in the weft direction, the widths of the first structural region and the third structural region are equal, and the widths of the second structural region and the fourth structural region are equal; and the width W of the first structural region A and the width W of the second structural region B satisfy the relationship: W A :W B > 1 to form a structure with a sunken middle and protruding surroundings.

[0013] As a further improvement of the present invention, in the weft direction, the widths of the first structural region and the third structural region are equal, and the widths of the second structural region and the fourth structural region are equal; and the width W of the first structural region A and the width W of the second structural region B satisfy the relationship: W A :W B = 1 to form a "checkerboard" structure with alternately distributed protrusions and depressions.

[0014] As a further improvement of the present invention, in the double-layer structural region, the first yarn segment of the broken-point padding weft yarn does not participate in the interweaving and is only padded between the surface tissue and the inner tissue of the double-layer structural region; in the single-layer structural region, the second yarn segment of the broken-point padding weft yarn participates in the interweaving.

[0015] As a further improvement of the present invention, the staple roving includes, but is not limited to, one or more mixtures of polyimide fiber, kapok fiber, and hemp fiber.

[0016] As a further improvement of the present invention, the staple roving of the broken-point padding weft yarn is hemp; the warp and weft yarn materials in the double-layer structural region and the single-layer structural region are fibers with moisture absorption lower than that of hemp, so as to form a unidirectional moisture conduction structure from the surface tissue to the staple roving in the double-layer structural region, and achieve rapid moisture conduction through the second yarn segment in the adjacent single-layer structure to keep the fabric surface dry.

[0017] In order to achieve the above-mentioned invention purpose, the present invention also provides a preparation method of the self-adjusting fabric according to any one of the foregoing technical solutions, including the following steps:

[0018] S1, determine the tissue structures of the first structural region, the second structural region, the third structural region, and the fourth structural region, and determine the ratio of the weft widths of the first structural region and the second structural region;

[0019] S2, select the warp yarn, weft yarn, and broken-point padding weft yarn of the predetermined raw materials; the broken-point padding weft yarn includes staple roving, water-soluble vinylon filaments continuously wrapped around the staple roving, and polyester filaments discontinuously wrapped around the staple roving to form alternately distributed first yarn segments without polyester filaments and second yarn segments with polyester filaments;

[0020] S3. After warping and reed threading according to the drawing of the loom, weaving is carried out;

[0021] Wherein, in the first structural area and the fourth structural area, the broken-point filling weft yarn does not participate in the interweaving, but is only filled between the two layers of the double-layer tissue structure;

[0022] In the second structural area and the third structural area, the broken-point filling weft yarn participates in the interweaving;

[0023] S4. After weaving is completed and during the dyeing process, the first yarn segment of the broken-point filling weft yarn in the first structural area and the fourth structural area is untwisted and evenly dispersed and then filled in the double-layer structure area, so that the double-layer structure area bulges; due to the wrapping effect of the polyester filament, the second yarn segment of the broken-point filling weft yarn in the second structural area and the third structural area continues to interweave in the single-layer structure area in the form of yarn, and a self-adjusting fabric with a single-layer and double-layer concave-convex structure is obtained.

[0024] Beneficial effects

[0025] 1. The present invention provides a fabric with self-adjusting structure. During the processing of this fabric, due to the designed structure, the structure continuously self-adjusts and finally reaches the designed structure. In the present invention, a single repeating unit is set to include a first structural area and a fourth structural area arranged diagonally, a second structural area and a third structural area arranged diagonally, and a broken-point filling weft yarn arranged in the aforementioned structural areas. Adjacent repeating units are connected to form a pocket-like structure with the fourth structural area at the center, the first structural areas at the four corners, and the second and third structural areas at the four sides. Among them, the first structural area and the fourth structural area are double-layer tissues, and the second structural area and the third structural area are single-layer tissues. Please refer Figure 7 As shown, since the second and third structural areas are single-layer tissues, the number of warp yarns in the second structural area is the same as the number of warp yarns in the fourth structural area, and the number of weft yarns is the same as the number of weft yarns in the first structural area; the number of warp yarns in the third structural area is the same as the number of warp yarns in the first structural area, and the number of weft yarns is the same as the number of weft yarns in the fourth structural area. The warp and weft yarns in the second and third structural areas have a large tightness with each other, while the warp and weft yarns in the first and fourth structural areas have a small tightness with each other. Due to the buckling effect, the yarns in the second structural area with a large tightness tend to contract in the warp and weft directions. Along the warp direction, the warp yarns in the fourth structural area are pulled towards the second structural area, and along the weft direction, the weft yarns in the first structural area are pulled towards the second structural area; due to the buckling effect, the yarns in the third structural area with a large tightness respectively pull the warp yarns in the first structural area towards the third structural area along the warp direction and pull the weft yarns in the fourth structural area towards the third structural area along the weft direction ( Figure 7The arrows indicate the direction of the force). Considering the interaction relationship between the warp and weft yarns in the single-layer and double-layer structural areas, the yarns in the second and third structural areas stretch the yarns in the first and fourth structural areas towards the second and third structural areas. The first and fourth structural areas perform self-adjustment on the second and third structural areas connected to them, achieving a tightening effect. Since there are weft inserting yarns inside the first and fourth structural areas, obvious protrusions are formed in these two areas after tightening.

[0026] 2. The self-adjusting fabric provided by the present invention changes the structure of the weft inserting yarn on the basis of the traditional double-layer weft inserting structure, and adopts a break-point weft inserting yarn composed of staple roving, water-soluble vinylon filaments continuously wrapped around the outer periphery of the staple roving, and polyester filaments intermittently wrapped around the outer periphery of the staple roving. The break-point weft inserting yarn includes a first yarn segment without polyester filaments and a second yarn segment with polyester filaments that are alternately distributed; taking advantage of the water-soluble characteristics of the vinylon filaments, after the fabric undergoes the dyeing process, the continuous water-soluble vinylon filaments in the break-point weft inserting yarn dissolve, the yarn structure of the first yarn segment is damaged and disintegrated, and the yarn structure of the second yarn segment is not disintegrated due to the dissolution of the water-soluble vinylon filaments because of the action of the polyester filaments. At the same time, during the weaving process of the present invention, the first yarn segment in the double-layer structural area disintegrates, and the staple roving untwists and disperses in the double-layer fabric, so that the first and fourth structural areas are filled with loose fibers. The loose fibers are fluffy and protrude, cooperating with the fabric structure to achieve the self-adjustment function, so that the fabric presents a three-dimensional rectangular array arrangement structure with local protrusions, and a protrusion effect will be generated on the fabric surface, realizing local contact instead of planar full contact; the single-layer structure can better contrast the protrusion effect, and the adjacent single-layer structural areas can form a functional continuous conduction channel. The four structural areas cooperate with each other, further better promoting the functional characteristics of the fabric. At the same time, due to the protection of the polyester filaments on the second yarn segment of the break-point weft inserting yarn, the second yarn segment participates in the formation of the fabric structure in the single-layer structural area in the form of yarns, improving the stability of the fabric structure in the single-layer structural area and solving the problem of structural instability caused by the dissolution of water-soluble vinylon.

[0027] 3. In the present invention, the area size ratio of the first structural area, the second structural area, the third structural area, and the fourth structural area can be adjusted according to needs, the organizational structure is flexible and variable, and the adjustment range is wide. By forming the second and third structural areas that form the single-layer structural area to connect the adjacent first and fourth structural areas, the adjacent setting, diagonal connection of the double-layer structural area and the single-layer structural area, and the protection of the structure by the break-point weft inserting yarn in the single-layer structural area, the fabric structure of the present invention is more stable, and the distribution of the introduced functional weft inserting yarn in the fabric is more uniform and controllable.

[0028] 4. The self-adjusting fabric provided by the present invention, based on the three-dimensional rectangular array arrangement structure with local protrusions, can achieve different functional requirements of the fabric by selecting filling weft yarns with different functional characteristics, and has great development prospects in the fields of building wall coverings, outdoor products, baby products, washable air-conditioning soft cool mats, functional insoles, etc.

[0029] 5. The preparation method of the self-adjusting fabric provided by the present invention has strong controllability, no additional production processes are added, the product development cost is reduced, the adjustable range of product functionality is wide, and the competitive advantage is strong. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 FIG. is a schematic structural diagram of Embodiment 1 of the self-adjusting fabric of the present invention.

[0031] Figure 2 FIG. is the drawing-in diagram of Embodiment 1.

[0032] Figure 3 FIG. is a schematic structural diagram of the wear-resistant device used in the present invention.

[0033] Figure 4 FIG. is a schematic structural diagram of Embodiment 3 of the self-adjusting fabric of the present invention.

[0034] Figure 5 FIG. is a schematic structural diagram of Embodiment 4 of the self-adjusting fabric of the present invention.

[0035] Figure 6 FIG. is a schematic structural diagram of the break-point filling weft yarn.

[0036] Figure 7 FIG. is a schematic diagram of the force condition of the yarns in each structural area of the self-adjusting fabric of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0037] The technical solutions of each embodiment of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments; all other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope protected by the present invention.

[0038] Please refer to Figures 1 to 7 as shown, the present invention provides a preparation method of a self-adjusting fabric, including the following steps:

[0039] S1. Determine the tissue structures of the first structural area, the second structural area, the third structural area, and the fourth structural area, and determine the ratio of the weft widths of the first structural area and the second structural area;

[0040] S2. Select the warp yarns, weft yarns, and break-point filling weft yarns of the predetermined raw materials;

[0041] S3, After threading the warp threads and reed according to the draft, start weaving;

[0042] Among them, in the first structural area and the fourth structural area, the broken-point filling weft yarn does not participate in the interweaving, but is only padded between the two layers of the double-layer organizational structure;

[0043] In the second structural area and the third structural area, the broken-point filling weft yarn participates in the interweaving;

[0044] S4, After the weaving is completed, during the dyeing process, the first yarn segments of the broken-point filling weft yarns in the first structural area and the fourth structural area are untwisted and dispersed and then filled in the double-layer structural area, making the double-layer structural area bulge; the second yarn segments of the broken-point filling weft yarns in the second structural area and the third structural area continue to interweave in the single-layer structural area in the form of yarns, obtaining a self-adjusting fabric with a single-and-double-layer concave-convex structure.

[0045] Among them, step S1 includes the following steps:

[0046] S11, Determine the organizational structures of the first structural area A and the fourth structural area D, both of which adopt one of the basic weaves or modified weaves to form a double-layer structural area; determine the organizational structures of the second structural area B and the third structural area C, and adopt one of the basic weaves or modified weaves to form a single-layer structure;

[0047] S12, Determine the ratio of the weft widths of the first structural area and the second structural area; among them, the weft width W A of the first structural area and the weft width W B of the second structural area, the ratio relationship can be W A :W B < 1, such as the structure shown in Figure 1 ; it can also be W A :W B = 1, such as the structure shown in Figure 4 ; it can also be W A :W B > 1, such as the structure shown in Figure 5 ;

[0048] S13, Determine the yarn arrangement ratios of the first structural area, the second structural area, the third structural area, and the fourth structural area. Those skilled in the art should understand that in the first structural area and the fourth structural area, the ratio of the surface warp yarn to the inner warp yarn can be one of 1:1, 2:1, 2:2, or other ratios, which can be set according to the product design requirements, and are not specifically limited; the ratio of the surface weft yarn to the inner weft yarn can be one of 1:1, 2:1, 2:2, or other ratios, which can be set according to the product design requirements, and are not specifically limited.

[0049] Please refer to Figure 6As shown, in step S2, the break-point filling weft yarn includes staple roving, a water-soluble vinylon filament 1 continuously wrapped around the outer periphery of the staple roving, and a polyester filament 2 intermittently wrapped around the outer periphery of the staple roving, forming alternating first yarn segments a and second yarn segments b. In the break-point filling weft yarn, the water-soluble vinylon filament 1 is a continuous filament, and the polyester filaments 2 are arranged at intervals. According to the ratio relationship between the weft width W A of the first structural region A B and the weft width W a of the second structural region B A to determine the ratio of the first yarn segments a and the second yarn segments b of the break-point filling weft yarn. Specifically, within the first structural region A, the length L a of the first yarn segment a along the weft direction is consistent with the weft width W b of the first structural region A; within the fourth structural region D, the length L B of the first yarn segment a along the weft direction is consistent with the weft width of the fourth structural region D; within the second structural region B, the length L b of the second yarn segment b along the weft direction is consistent with the weft width W

[0050] of the second structural region B; within the third structural region C, the length L

[0051] of the second yarn segment b along the weft direction is consistent with the width of the third structural region C. Among them, the first yarn segment a is composed of staple roving and the water-soluble vinylon filament 1 wrapped around the staple roving, and the second yarn segment b is composed of staple roving, the water-soluble vinylon filament 1 wrapped around the staple roving, and the polyester filament 2; that is, the yarn segment without the polyester filament 2 wrapped is the first yarn segment a, and the yarn segment with the polyester filament 2 wrapped is the second yarn segment b. In step S3, the break-point filling weft yarn is correspondingly put in, that is, in the first structural region A and the fourth structural region D, it corresponds to the first yarn segment a of the break-point filling weft yarn without the polyester filament 2 wrapped, and in the second structural region B and the third structural region C, it corresponds to the second yarn segment b wrapped with the polyester filament 2.In step S4, after the weaving is completed and the fabric is taken off the loom, the fabric is subjected to scouring treatment at a temperature higher than 85°C, and then washed with water. The washing dissolves the water-soluble vinylon 1 of the broken-end filling weft yarn. After washing, the fabric is dyed. The dyeing is carried out using an overflow jet dyeing machine. During dyeing, the fabric is subjected to an external force impact. The first yarn segment a without the wrapping of the polyester filament 2 disintegrates under the action of the external force. The second yarn segment b with the polyester filament 2 still exists in the fabric in the form of yarn due to the protection of the polyester filament 2. The broken-end filling weft yarns in the first structural region A and the fourth structural region D are untwisted and evenly dispersed and then filled in the double-layer structural regions A and D, making the structural regions bulge. Due to the wrapping effect of the polyester filament 2, the broken-end filling weft yarns in the second structural region B and the third structural region C continue to be interwoven in the form of yarns in the single-layer structural region, obtaining a fabric with a single and double-layer concave-convex structure. This method does not require specific additional processes, only needs to adjust the process conditions, and the process flow does not increase, which is beneficial to cost control.

[0052] With such a setting, at the double-layer structure, the broken-end filling weft yarn is padded into the two layers of fabric in the form of a water-soluble vinylon filament 1 wrapping a staple roving. Compared with the traditional functional yarn being exposed on the fabric surface in the form of weave points, it effectively reduces the requirements for the spinnability and weavability of the filling weft yarn, has a wide application range, can use fibers with poor spinnability that cannot be used in traditional processes, and realizes the regeneration of waste raw materials; it avoids the defects that the filling weft yarn in the traditional process affects the appearance, hand feeling and wearing comfort of the fabric, and effectively reduces the wear of the functional yarn and prolongs the service life of the fabric; in addition, since the filling weft yarn is filled between the double-layer tissues, the wash resistance of the fabric is improved. Also, the functional yarn in the broken-end filling weft yarn is interwoven in the fabric in the form of yarn in the single-layer structural region, improving the stability of the fabric and avoiding the problem of the exposure of functional fibers caused by fiber untwisting.

[0053] The following describes the self-adjusting fabrics with different structures provided by the present invention in combination with Examples 1 to 4:

[0054] Example 1

[0055] A preparation method of a self-adjusting functional wall fabric:

[0056] S1, it is determined that the surface and bottom tissues of the first structural region A and the fourth structural region D both adopt plain weave to form a double-layer tissue; the second structural region B and the third structural region C both adopt a 2 / 2 twill weave to form a single-layer structure; it is determined that the ratio of the weft width of the first structural region to the second structural region is W A :W B = 1:4;

[0057] S2, determine the materials of the warp yarns, weft yarns, and broken-point padding weft yarns in the first structural region A, the second structural region B, the third structural region C, and the fourth structural region D (as shown in Table 1); according to Table 1, the broken-point padding weft yarn is composed of kapok roving, water-soluble vinylon filaments 1 continuously wrapped around the kapok roving, and polyester filaments 2 intermittently wrapped around the kapok roving;

[0058] S3, perform warping and reed threading according to the draft (as Figure 2 shown) and then carry out weaving;

[0059] Among them, in the first structural region A and the fourth structural region D, the broken-point padding weft yarn does not participate in interlacing and only pads between the two layers of the double-layer tissue structure; in the second structural region B and the third structural region C, the broken-point padding weft yarn participates in interlacing;

[0060] S4, after weaving is completed, perform scouring treatment on the fabric. When treating, the temperature is higher than 85°C, then wash with water, and dye after washing. Use an overflow jet dyeing machine for dyeing. When dyeing, the fabric is subjected to an external force impact, so that the broken-point padding weft yarns in the first structural region A and the fourth structural region D are untwisted, evenly dispersed, and filled in the double-layer structure region to form protrusions; in the second structural region B and the third structural region C, since the polyester filaments 2 are insoluble in water, the broken-point padding weft yarns still maintain the yarn structure and participate in interlacing to obtain a self-adjusting fabric with a concave-convex structure.

[0061] During the weaving process, when every four weft yarns are beaten in, a group of broken-point padding weft yarns are padded. The weaving process parameters and raw material settings are as shown in Table 1 below.

[0062] Table 1 Organizational structure design and weaving process parameter settings of Example 1

[0063]

[0064]

[0065] Please refer to Figure 1 shown, the self-adjusting fabric prepared in Example 1 includes a number of repeating units arranged in an array structure. Each individual repeating unit includes a first structural region A and a fourth structural region D arranged diagonally, and a second structural region B and a third structural region C arranged diagonally. Among them, the first structural region A and the fourth structural region D are double-layer tissues composed of a surface tissue and a lining tissue, arranged in a left diagonal; the second structural region B and the third structural region C are single-layer tissues, arranged in a right diagonal.

[0066] Please refer to Figure 7As shown, where the arrows indicate the direction of the force. Since the second and third structural regions B and C are single-layer tissues, the number of warp yarns in the second structural region B is the same as that in the fourth structural region D, and the number of weft yarns is the same as that in the first structural region A; the number of warp yarns in the third structural region C is the same as that in the first structural region A, and the number of weft yarns is the same as that in the fourth structural region D. The warp and weft yarns in the second and third structural regions B and C have a large tightness with each other, while the warp and weft yarns in the first and fourth structural regions A and D have a small tightness with each other. Due to the buckling effect, the yarns in the second structural region B with a large tightness show a shrinking trend for the warp and weft yarns. Along the warp direction, the warp yarns in the fourth structural region D are pulled towards the inside of the second structural region B, and along the weft direction, the weft yarns in the first structural region A are pulled towards the inside of the second structural region B; due to the buckling effect, the yarns in the third structural region C with a large tightness pull the warp yarns in the first structural region A towards the inside of the third structural region C along the warp direction and pull the weft yarns in the fourth structural region D towards the inside of the third structural region C along the weft direction. Considering the interaction relationship between the warp and weft yarns in the single- and double-layer structural regions, the yarns in the second and third structural regions B and C stretch the yarns in the first and fourth structural regions A and D towards the second and third structural regions B and C. The first and fourth structural regions A and D perform a self-adjustment of the structure on the second and third structural regions B and C connected to them, achieving a tightening effect. Since there are filling weft yarns inside the first and fourth structural regions A and D, obvious protrusions are formed after tightening. In this way, the self-adjustment achieved in the fabric structure, on the one hand, reduces the weaving difficulty caused by the shrinkage rate difference during the weaving of the single- and double-layer tissue alternating structure; at the same time, the larger buckling of the single-layer tissues (the second and third structural regions B and C) on the peripheral side assists in locking the double-layer tissues (the first structural region A and the fourth structural region D) in the center, which is beneficial to preventing the exposure of the broken-point filling weft yarns. On the other hand, the single-layer tissue structure plays a role in stabilizing the overall fabric structure, and the fabric structure is flat and the weaving is convenient.

[0067] The broken-point filling weft yarn includes kapok staple fiber roving, a water-soluble vinylon filament 1 continuously wrapped around the kapok staple fiber roving, and a polyester filament 2 intermittently wrapped around the staple fiber roving and the water-soluble vinylon filament 1, forming an alternately distributed first yarn segment a and second yarn segment b. The length L of the first yarn segment a a , is the same as the weft width W of the first structural region A within the first structural region A A ; and is the same as the weft width W of the fourth structural region D within the fourth structural region D B . The length L of the second yarn segment b b , is the same as the weft width W of the second structural region B within the second structural region B B ; and is the same as the weft width W of the third structural region C within the third structural region C A . That is, within the first and second structural regions, the length ratio L of the first yarn segment a and the second yarn segment b of the broken-point filling weft yarna :L b = 1:4; In the fourth structural region and the third structural region, the length ratio L of the first yarn segment a and the second yarn segment b of the break point filling weft yarn a :L b = 4:1, so that the first yarn segment and the second yarn segment of the break point filling weft yarn respectively correspond to and match the single-layer and double-layer regions. Through the connection of the left diagonal and right diagonal structural regions, adjacent repeating units are connected to form a pocket-like structure with the fourth structural region at the center, the first structural region A at the four corners, and the second and third structural regions B and C at the four sides.

[0068] The first yarn segment a of the break point filling weft yarn arranged between the surface weave and the inner weave of the first structural region A and the fourth structural region D does not participate in the interweaving, but only pads between the two layers of the double-layer tissue structure. With this setting, compared with the traditional functional yarns exposed on the fabric surface in the form of weave points, the requirements for the spinnability and weavability of the break point filling weft yarn are effectively reduced, and the applicable range is wide. Fibers with poor spinnability that cannot be used in traditional processes can be used, realizing the regeneration of waste raw materials; avoiding the defects of the break point filling weft yarn in the traditional process affecting the appearance, feel and wearing comfort of the fabric, and effectively reducing the wear of the functional yarn, prolonging the service life of the fabric. In addition, since the break point filling weft yarn is filled between the double-layer tissues, the wash resistance of the fabric is improved. At the same time, due to the protection of the polyester filament 2 of the second yarn segment b for the second yarn segment b of the break point filling weft yarn, it participates in the formation of the fabric structure in the single-layer structural region, improving the stability of the fabric structure in the single-layer structural region and solving the problem of structural instability caused by the dissolution of the water-soluble vinylon filament.

[0069] In this embodiment, taking advantage of the water-soluble characteristic of the vinylon filament, after the fabric undergoes the dyeing process, the continuous water-soluble vinylon filaments in the break point filling weft yarn dissolve, and the yarn structure of the first yarn segment disintegrates. Due to the action of the polyester filament, the second yarn segment still maintains the shape of the yarn after the water-soluble vinylon filaments dissolve. Therefore, the first yarn segment padded into the double-layer structural region disintegrates, the kapok staple fiber roving untwists and disperses in the double-layer tissue, and fills inside the first and fourth structural regions. The loose fibers bulge, cooperate with the fabric tissue, and act synergistically to further realize the self-adjustment of the fabric structure, making the fabric present a three-dimensional rectangular array arrangement structure with local bulges, generating a bulging effect on the fabric surface, and the single-layer structural region can better contrast the bulging effect.

[0070] By adopting kapok fibers and water-soluble vinylon filaments wrapped around their surfaces to form the first yarn segment, and padding it into the first and fourth structural areas of the double-layer fabric, after dyeing, the kapok is distributed as loose fibers between the double layers, which can effectively absorb incident sound waves and provide the fabric with a sound-absorbing function. Due to the protective effect of polyester filaments on the yarn, the kapok roving participates in the interweaving in the form of yarn in the third and fourth structural areas, forming a single-layer structure at the right diagonal and being connected and configured with the raised double-layer structure at the left diagonal. The concave-convex structure formed on the self-adjusting fabric surface can effectively reflect the incident sound waves, realizing the absorption and reflection of sound, further improving the sound insulation effect, providing a good privacy protection function for the home environment, and at the same time, the kapok fibers also have good antibacterial properties.

[0071] Moreover, both the warp and weft yarns of the double-layer fabric are woven with polyimide (PI) yarns. Under the condition of flaming combustion, there is no melting, no dripping, low smoke and non-toxic, and it has characteristics such as flame retardancy, heat insulation, and antibacterial. The thermal protection coefficient of the fabric is 571.4 kW·s / m 2 , having good heat insulation and flame retardancy performance; the antibacterial property endows a good home environment and increases the service life of the wall covering, making the self-adjusting functional wall covering fabric have excellent flame retardancy performance, sound insulation effect and antibacterial property.

[0072] Comparative Example 1

[0073] For effect comparison, according to the prior art, Comparative Example 1 was woven, and its organizational structure design and weaving process parameters are shown in Table 2. Comparative Example 1 keeps the fabric organizational structure and process parameters the same as those in Example 1, and changes the warp and weft yarn raw materials to white flame-retardant cotton, and changes the broken-point padding weft yarn to a padding weft yarn with raw material of red flame-retardant cotton.

[0074] Through comparative analysis with Example 1, it can be seen that the self-adjusting functional wall covering fabric prepared in Comparative Example 1 has the defect of decreased flame retardancy performance. Its limiting oxygen index value is 26.4%, which is between 22% and 27%, belonging to a combustible fabric. And its thermal protection performance has decreased compared with Example 1, and the thermal protection coefficient TPP value is 419.2 kW·s / m 2 . And the sound absorption effect and antibacterial property of the wall covering in Comparative Example 1 have decreased compared with Example 1.

[0075] Table 2 Organizational structure design and weaving process parameter settings of Comparative Example 1

[0076]

[0077] Please refer to Figure 3As shown in the figure, in order to verify that the polyester filament 2 in the second yarn segment of the break point filling weft yarn in the first embodiment effectively protects the yarn structure and is beneficial to improving the stability of the fabric structure in the single-layer structure area, a wear-resistant device 200 developed by ourselves is used to test the wear resistance of the single-layer areas in the first embodiment and the comparative example. In the comparative example, the filling weft yarn is not intermittently wrapped with polyester filaments, that is, it is only composed of staple fiber roving and water-soluble vinylon filaments wrapped around the outer periphery of the staple fiber roving. The wear-resistant device 200 includes a sample fixing component 22 for fixing the sample 21 and a friction component. The friction component includes a friction head 23 and 400-mesh sandpaper 24, and the diameter of the friction head 23 is 1 cm.

[0078] The test method is as follows: Under the conditions of a test temperature of 21 °C and a relative humidity of 63%, the pre-tension of the friction component is 5 N, the friction method is friction head rotation friction, and the number of friction times is ten turns. After friction, the loose fibers in the friction area are collected. By observing the proportion of different fibers rubbed off on the sandpaper under a microscope, the yarn structure and the stability of the single-layer structure area are studied under the conditions of the staple fiber roving with and without polyester filament wrapping. The specific test data are shown in Table 3.

[0079] Table 3 Wear resistance test data of the first embodiment and the comparative example

[0080]

[0081] As can be seen from Table 3, the proportion of fibers rubbed off from the roving in the second yarn segment of the break point filling weft yarn in the first embodiment with spaced polyester filaments is less than that of the filling weft yarn in the comparative example without polyester filament protection. This shows that the design of the break point filling weft yarn effectively protects the yarn structure of the second yarn segment and is beneficial to improving the stability of the fabric structure in the single-layer structure area.

[0082] The second embodiment

[0083] Preparation of a self-adjusting woven thermal fabric:

[0084] The difference from the first embodiment lies in: the differences in the fabric material, structure design and weaving process parameters, as shown in Table 4 specifically. The other steps are basically the same and will not be elaborated here.

[0085] Table 4 Organizational structure design and weaving process parameter settings of the second embodiment

[0086]

[0087]

[0088] In the fabric, similar to Example 1, the A and D structural regions form a double-layer tissue with fluffy protrusions. The surface tissue component is PI, providing good heat insulation, moisture-proof, and antibacterial properties; the inner layer tissue component is cotton, providing good wearing comfort. After the break point filling weft yarn is untwisted, the PI staple fiber yarn is distributed in a loose fiber form between the double-layer fabrics. The fluffiness of the loose fibers and the heat insulation performance of PI endow the fabric with better heat insulation and heat preservation effects, and the thermal resistance value is 0.158 m 2 ·°C·W -1 . Thus, while the fabric takes into account comfort, it has the properties of warmth retention, flame retardancy, antibacterial, and moisture-proof. In the B and C structural regions, a stable single-layer tissue is formed, which improves the stability of the double-layer tissue and is conducive to the uniform distribution of the filling weft yarn in the fabric after untwisting.

[0089] The light and warm fabric makes full use of the good heat insulation performance of PI fibers and can be used for fabrics such as underlay rugs and sleeping bags for tents in the outdoors or during marches.

[0090] Comparative Example 2

[0091] Compared with Example 2, in Comparative Example 2, the organizational structure and weaving process parameters are kept unchanged, and only the raw materials are changed: the warp and weft yarns and the filling weft yarn raw materials in the first to fourth structural regions are all made of pure cotton, and a comparative warm woven fabric is prepared. It can be tested that its thermal resistance value drops to 0.028 m 2 ·°C·W -1 .

[0092] Example 3

[0093] A preparation method of a self-adjusting insole fabric:

[0094] The difference from Example 1 is that: the weft width ratio of the first structural region A and the second structural region B is W A :W B = 1:1, the fabric design and weaving process parameters are different, as shown in Table 5 specifically, and the other steps are basically the same and will not be elaborated here.

[0095] Table 5 shows the organizational structure design and weaving process parameter settings of Example 3

[0096]

[0097] The self-adjusting insole fabric, similar to Example 1, has protrusions formed in the A and D structural regions; depressions and stable structures are formed in the B and C structural regions. The difference is that: due to W A :W B = 1:1, the widths of the A and B regions of the obtained insole fabric are also 1:1, and the insole fabric is generally in the form of a checkerboard (such as Figure 4As shown in the figure, this concave-convex structure is conducive to increasing the friction between the sole and the insole, avoiding slippage between the sole and the insole during rapid movement. Further, the arrangement position of the double-layer tissue can be set according to the distribution of human foot acupoints. Through the fabric structure and the thickness of the filling weft yarn, obvious raised squares are formed at the fixed-point positions of the insole, so as to realize the foot massage function.

[0098] In the dyeing and processing process, after the hemp fibers in the first yarn segment are untwisted, they are distributed between the double-layer tissues. The double-layer structure area is in local contact with the sole as the surface layer. The surface warp and weft yarns are made of polyimide yarns, and the fabric inner layer adhered to the foam layer uses high-f number fine denier nylon for the inner warp and inner weft; with such a setting, a unidirectional moisture conduction structure is formed from the surface layer tissue (polyimide) to the filling weft yarn (hemp), which is conducive to the absorption of sweat. The second yarn segment of the broken filling weft yarn is distributed in the single-layer structure area, and the adjacent single-layer structure areas are connected to form a moisture conduction path, realizing rapid moisture conduction, keeping the fabric surface dry, thereby destroying the growth environment of bacteria, making the bacteria lose their vitality, and at the same time providing wearing comfort. At the same time, from the perspective of raw material setting, the filling weft yarn hemp has strong moisture absorption, natural antibacterial properties and adsorption properties; the polyimide in local contact with the sole has excellent natural antibacterial properties, has broad-spectrum antibacterial characteristics, and no free silver nanoparticles are precipitated. The prepared self-adjusting insole fabric has an antibacterial rate of 98% against Escherichia coli (standard value ≥

[0099] 70%), 98% antibacterial rate against Staphylococcus aureus (standard value ≥ 70%), and 90% antibacterial rate against Candida albicans (standard value ≥ 60%), indicating that the fabric has excellent antibacterial properties. The insole fabric made of this fabric has the functions of removing odor, antibacterial, moisture conduction and ventilation, and has high wearing comfort.

[0100] Example 4

[0101] A preparation method of a self-adjusting dry sweat storage / wet fabric:

[0102] Table 6 Organizational structure design and weaving process parameter settings of Example 4

[0103]

[0104] The self-adjusting dry sweat storage / wet fabric is similar to that in Example 1, and raised areas are formed in areas A and D; sunken stable structures are formed in areas B and C. The difference is that since W A :W B =4:1>1, the widths of areas A and B of the obtained self-adjusting dry sweat storage / wet fabric are also 4:1. The double-layer area of the fabric is raised, and the single-layer area is sunken, and the appearance is generally a structure with high edges and low middle (as Figure 5As shown). Further, a moisture absorption and ventilation channel is formed along the diagonal of the single-layer structure, which is beneficial to the rapid discharge of sweat and moisture; the local contact between the fabric surface and the skin is beneficial to keeping the skin surface dry.

[0105] The fabric can be used for baby sweat-absorbing towels, skin-friendly fabrics, fabric layers on urine pads (for babies / patients), washable air-conditioning soft cooling mats, etc.

[0106] It should be noted that those skilled in the art should understand that in the foregoing embodiments, the weft width W of the first structural region A and the weft width W of the second structural region B The proportional relationship is not limited to the set value in the embodiment. When W A :W B <1, it can also be W A :W B =1:2, or W A :W B =1:6, or W A :W B =1:8, or W A :W B =1:10 or other values, only need to satisfy W A :W B <1, and they will not be listed one by one here; similarly, when W A :W B >1, the values can also be set according to the design and functional requirements of the actual product, which will not be elaborated here.

[0107] It should also be noted that in practical applications, according to functional requirements, the staple roving can be replaced with other functional staple rovings or a mixture of other multiple functional staple rovings.

[0108] In summary, the present invention provides a self-adjusting fabric and a method for preparing the same. The self-adjusting fabric includes a plurality of repeating units arranged in an array structure. A single repeating unit includes a first structural region and a fourth structural region arranged diagonally, a second structural region and a third structural region arranged diagonally, and break-point filling weft yarns disposed in the foregoing structural regions. The first structural region and the fourth structural region are double-layer tissues, and the second structural region and the third structural region are single-layer tissues. The break-point filling weft yarns include staple roving, water-soluble vinylon filaments continuously wrapped around the staple roving, and polyester filaments intermittently wrapped around the staple roving, forming first yarn segments without polyester filaments and second yarn segments with polyester filaments that are alternately distributed. The first yarn segments are correspondingly disposed between the double-layer tissues of the first structural region and the fourth structural region. During dyeing and processing, the break-point filling weft yarns in the first structural region and the fourth structural region untwist, are evenly dispersed, and then fill the double-layer structural regions, causing the structural regions to bulge. Due to the wrapping effect of the polyester filaments, the break-point filling weft yarns in the second structural region and the third structural region continue to interweave in the single-layer structural regions in the form of yarns, obtaining a self-adjusting fabric with a single- and double-layer concave-convex structure. Moreover, the self-adjusting fabric provided by the present invention can meet different functional requirements of the fabric by selecting break-point filling weft yarns with different functional characteristics.

[0109] As described above, the above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution of the present invention and its inventive concept, makes equivalent substitutions or changes, and all should be covered within the protection scope of the present invention.

Claims

1. A self-adjusting fabric, characterized in that: The self-adjusting fabric includes a number of repeating units arranged in an array structure; a single repeating unit includes a first structural area and a fourth structural area arranged diagonally, a second structural area and a third structural area arranged diagonally, and a broken-point filling weft yarn disposed in the foregoing structural areas; the broken-point filling weft yarn includes staple roving, a water-soluble vinylon filament continuously wrapped around the staple roving, and a polyester filament intermittently wrapped around the staple roving to form an alternately distributed first yarn segment and second yarn segment; The first structural area and the fourth structural area are double-layer tissues composed of a surface tissue and a lining tissue, forming a double-layer structural area, and the first yarn segment of the broken-point filling weft yarn is correspondingly disposed between the surface tissue and the lining tissue; the first yarn segment is composed of staple roving and a water-soluble vinylon filament wrapped around the staple roving; and in the first structural area, the length of the first yarn segment is consistent with the width of the first structural area along the weft direction; in the fourth structural area, the length of the first yarn segment is consistent with the width of the fourth structural area along the weft direction; The second structural area and the third structural area are single-layer tissues, forming a single-layer structural area; the second yarn segment includes staple roving, a water-soluble vinylon filament continuously wrapped around the staple roving, and a polyester filament continuously wrapped around the staple roving; and in the second structural area, the length of the second yarn segment is consistent with the width of the second structural area along the weft direction; in the third structural area, the length of the second yarn segment is consistent with the width of the third structural area along the weft direction; In the double-layer structural area, the first yarn segment of the broken-point filling weft yarn does not participate in interweaving and is only padded between the surface tissue and the lining tissue of the double-layer structural area; in the single-layer structural area, the second yarn segment of the broken-point filling weft yarn participates in interweaving; During the dyeing process, the first yarn segment of the broken-point filling weft yarn in the first structural area and the fourth structural area is untwisted, uniformly dispersed and filled in the double-layer structural area, so that the double-layer structural area bulges; due to the wrapping effect of the polyester filament, the second yarn segment of the broken-point filling weft yarn in the second structural area and the third structural area continues to interweave in the single-layer structural area in the form of yarns, obtaining a self-adjusting fabric with a single-layer and double-layer concave-convex structure.

2. The self-adjusting fabric according to claim 1, wherein: In the weft direction, the widths of the first structural region and the third structural region are equal, and the widths of the second structural region and the fourth structural region are equal; and the width W of the first structural region A and the width W of the second structural region B satisfy the relation: W A :W B <1, so as to form a structure that bulges in the middle and depresses around.

3. The self-adjusting fabric according to claim 1, characterized in that: In the weft direction, the widths of the first structural region and the third structural region are equal, and the widths of the second structural region and the fourth structural region are equal; and the width W of the first structural region A and the width W of the second structural region B satisfy the relationship: W A :W B > 1, so as to form a structure with a middle depression and convexity around the perimeter.

4. The self-adjusting fabric according to claim 1, characterized in that: In the weft direction, the widths of the first structural region and the third structural region are equal, and the widths of the second structural region and the fourth structural region are equal; and the width W of the first structural region A and the width W of the second structural region B satisfy the relation: W A :W B = 1, so as to form a "checkerboard" structure with alternately distributed protrusions and depressions.

5. The self-adjusting fabric according to claim 1, wherein: The staple roving includes, but is not limited to, one or more mixtures of polyimide fiber, kapok fiber, and hemp fiber.

6. The self-adjusting fabric according to claim 5, wherein: The staple roving of the broken-point filling weft yarn is hemp; the warp and weft yarn materials in the double-layer structural area and the single-layer structural area are fibers with a moisture absorption lower than that of hemp, so as to form a one-way moisture conduction structure from the surface tissue to the staple roving in the double-layer structural area, and realize rapid moisture conduction through the second yarn segment in the adjacent single-layer structure to keep the fabric surface dry.

7. A method for preparing the self-adjusting fabric according to any one of claims 1 to 6, characterized in that, Including the following steps: S1, determine the tissue structures of the first structural area, the second structural area, the third structural area, and the fourth structural area, and determine the ratio of the weft width of the first structural area to the second structural area; S2, select the warp yarns, weft yarns and break-point padding weft yarns of the predetermined raw materials; the break-point padding weft yarns include staple roving, water-soluble vinylon filaments continuously wrapped around the staple roving, and polyester filaments discontinuously wrapped around the staple roving, so as to form first yarn segments without polyester filaments and second yarn segments with polyester filaments that are alternately distributed; S3, perform weaving after threading the warp and reed according to the harness plan; Among them, in the first structural area and the fourth structural area, the break-point padding weft yarns do not participate in the interweaving and are only padded between the two layers of the double-layer tissue structure; In the second structural area and the third structural area, the break-point padding weft yarns participate in the interweaving; S4, after the weaving is completed, during the dyeing process, the first yarn segments of the break-point padding weft yarns in the first structural area and the fourth structural area are untwisted and uniformly dispersed and then filled in the double-layer structure area, so that the double-layer structure area bulges; due to the wrapping effect of the polyester filaments, the second yarn segments of the break-point padding weft yarns in the second structural area and the third structural area continue to be interwoven in the single-layer structure area in the form of yarns, and a self-adjusting fabric with a single and double-layer concave-convex structure is obtained.

Images