Manufacturing method and fabric of multi-layered velvet-like light-blocking curtain fabric

Abstract

The present application relates to a manufacturing method and a fabric of a multi-layer velvet-like light-shielding curtain fabric. The method includes: S100, manufacturing a grey yarn for imitation wool yarn, which is used as weft yarn A, and manufacturing weft yarn B; S200, manufacturing warp yarn A and warp yarn B, where warp yarn A is black; S300, using the above warp yarn A, weft yarn A and weft yarn B to manufacture an upper structure and a lower structure, and using warp yarn B to weave the upper structure and the lower structure together to form a fabric, wherein the upper structure and the lower structure are connected by a tying warp. The above method of the present application is conducive to making a fabric with good velvet feeling, environmental protection and good light-shielding performance. Through the optimization of materials and related process parameters, it is possible to achieve a velvet feeling similar to that of wool at a lower cost, and a light-shielding rate of 99.9999%, and at the same time, the method is relatively environmentally friendly.

Description

Technical Field

[0001] The present application relates to the field of curtain fabric manufacturing, in particular to a manufacturing method and fabric of a multi-layered velvet-like light-shielding curtain fabric. Background Art

[0002] Curtains are commonly used items in daily life for blocking light. The development trend of curtains is to require good light-shielding performance while having a good touch feeling, giving people a warm and comfortable experience. In the prior art, in order to pursue the light-shielding performance of curtains, coating, laminating and other processing techniques are mostly used. However, the coating is prone to aging and peeling, and organic solvents are prone to volatilization, resulting in excessive harmful substances in the room. Moreover, the prior art cannot produce a curtain fabric with good velvet feeling, environmental protection and good light-shielding performance. Summary of the Invention

[0003] Based on this, a manufacturing method of a multi-layered velvet-like light-shielding curtain fabric is provided. The fabric made by this method has a good velvet feeling, is environmentally friendly, and has good light-shielding performance.

[0004] The manufacturing method of the multi-layered velvet-like light-shielding curtain fabric includes:

[0005] S100. Making a base yarn for imitating wool yarn, using the base yarn as weft yarn A, and making weft yarn B.

[0006] S200. Making warp yarn A and warp yarn B, and warp yarn A is black.

[0007] S300. Using the above-mentioned warp yarn A, weft yarn A and weft yarn B to make an upper structure and a lower structure, and using warp yarn B to weave the upper structure and the lower structure together to form a fabric, wherein the upper structure and the lower structure are connected by a binding warp.

[0008] The above method of the present application is beneficial to making a fabric with good velvet feeling, environmental protection and good light-shielding performance. By optimizing the materials and related process parameters, it is possible to achieve a velvet feeling similar to that of wool at a lower cost, and have a light-shielding rate of 99.99%. At the same time, this method is more environmentally friendly.

[0009] In one embodiment, it further includes step S400, and step S400 is: dye the fabric formed in step S300, specifically including: degreasing and refining the fabric at 90°C, and dyeing the fabric after degreasing and refining is completed. The control method of the dyeing temperature is as follows: in the range of 30°C - 60°C, the heating rate is 2.5°C / min; in the range of 61°C - 110°C, the heating rate is 1.5°C / min; in the range of 111°C - 125°C, the heating rate is 0.8°C / min; at a temperature of 125°C, keep warm for 55 minutes, and then cool down. In the range of 125°C - 30°C, the cooling rate is 2°C / min. It also includes S500: shape the fabric after dyeing in step S400, specifically including: shaping the fabric using a shaping machine, the shaping temperature is 175°C, and the running speed of the shaping machine is 16 m / min.

[0010] In one embodiment, in step S300, the method of using the above-mentioned warp A, weft A, and weft B to make the upper structure and the lower structure includes: using warp A to weave with weft A and weft B to form the surface layer and the first intermediate layer of the fabric, and the surface layer and the first intermediate layer form the upper structure. Among them, weft A corresponds to the surface layer, and weft B corresponds to the first intermediate layer;

[0011] Using warp A to weave with weft A and weft B to form the inner layer and the second intermediate layer of the fabric, and the inner layer and the second intermediate layer form the lower structure. Among them, weft A corresponds to the inner layer, and weft B corresponds to the second intermediate layer.

[0012] In one embodiment, the warp density is 148 threads / cm, the weft density is 48 threads / cm, and the arrangement ratio of weft A to weft B is 1:1. Among them, the conveying speed of warp A corresponding to the upper structure is S1, the conveying speed of warp A corresponding to the lower structure is S2, and the conveying speed of warp B is S3. The ratio of S2:S1:S3 is 1.24:1.2:1.

[0013] In one embodiment, prepare material d, and material d is: 75D / 72F - polyester - semi - dull - DTY - black. Add 450 twists per meter to material d, and use material d as warp A.

[0014] Prepare material e, and material e is: 75D / 36F - polyester - semi - dull - DTY. Add 420 twists per meter to material e, and use the material as warp B.

[0015] The weft B is: 75D / 72F - polyester - semi - dull - DTY - black.

[0016] In one embodiment, in step S100, the specific manufacturing process of weft yarn A includes: preparing 2 parts of material a, where material a is 150D / 288F - polyester - semi - dull - DTY, and material a is used as the wool - like yarn for the pile yarn; 1 part of material b, where material b is 150D / 96F - polyester semi - dull - DTY - high shrinkage, and material b is used as the core yarn for the wool - like yarn; 1 part of material c, where material c is 150D / 48F - polyester - semi - dull - DTY, and material c is used as the covering yarn for the wool - like yarn. Feed 2 parts of material a, 1 part of material b, and 1 part of material c into the twisting equipment through 4 rollers respectively. Among them, the feeding speed ratio of material a, material b, and material c is 2.17:1:1.15.

[0017] In one embodiment, the feeding speed of material a is 56.4 m / min, the feeding speed of material b is 26 m / min, and the feeding speed of material c is 30 m / min.

[0018] A multi - layer velvet - like light - blocking curtain fabric, which is made by the manufacturing method of the multi - layer velvet - like light - blocking curtain fabric. Detailed implementation manners

[0019] To make the above - mentioned objects, features, and advantages of the present application more obvious and understandable, the following provides a detailed description of the specific implementation manners of the present application.

[0020] The embodiments of the present application provide a manufacturing method of a multi - layer velvet - like light - blocking curtain fabric, and the method includes:

[0021] S100. Produce the base yarn of the wool - like yarn, and use the base yarn as weft yarn A, and produce weft yarn B.

[0022] S200. Produce warp yarn A and warp yarn B, and warp yarn A is black.

[0023] S300. Use the above - mentioned warp yarn A, weft yarn A, and weft yarn B to produce the upper structure and the lower structure, and use warp yarn B to weave the upper structure and the lower structure together to form the fabric. Among them, the upper structure and the lower structure are connected by the binding warp.

[0024] In one embodiment, it further includes step S400, and step S400 is: dye the fabric formed in step S300, specifically including: degrease and refine the fabric at 90°C, and then dye the degreased and refined fabric. The control method of the dyeing temperature is as follows: in the range of 30°C - 60°C, the heating rate is 2.5°C / min; in the range of 61°C - 110°C, the heating rate is 1.5°C / min; in the range of 111°C - 125°C, the heating rate is 0.8°C / min; keep the temperature at 125°C for 55 minutes, and then cool down. In the range of 125°C - 30°C, the cooling rate is 2°C / min. It also includes S500, that is, shape the fabric after the dyeing in step S400 is completed, specifically including: use a shaping machine to shape the fabric, and the shaping temperature is 175°C. For example, it can be 175°C, and the running speed of the shaping machine is 16 m / min. It should be noted that the above shaping temperature of 175°C is the lowest temperature that can ensure the fabric is dried and the fabric shape is stable, and the dimensional stability is the best. Setting the shaping temperature at 175°C and the running speed of the shaping machine at 16 m / min has the following advantages: the temperature is lower than the conventional one, and the speed is also slower than the conventional method. Although the output is reduced, this is more appropriate because one of the problems solved by the method of this application is to make the fabric have a better fluff feeling. Using the above shaping method, the fluff feeling of the produced fabric is the best, and the surface feel of the fabric will not be too hard due to the shaping process.

[0025] In one embodiment, in step S300, the method of using the above-mentioned warp A, weft A, and weft B to make the upper structure and the lower structure specifically includes: using warp A to weave with weft A and weft B to form the surface layer and the first intermediate layer of the fabric. The surface layer and the first intermediate layer form the upper structure. Among them, weft A corresponds to the surface layer, and weft B corresponds to the first intermediate layer; using warp A to weave with weft A and weft B to form the inner layer and the second intermediate layer of the fabric. The inner layer and the second intermediate layer form the lower structure. Among them, weft A corresponds to the inner layer, and weft B corresponds to the second intermediate layer. Among them, the surface layer and the inner layer are the two outer surfaces of the produced fabric, and the first intermediate layer and the second intermediate layer are adjacent.

[0026] In one embodiment, the warp density is 148 threads / cm, the weft density is 48 threads / cm, and the arrangement ratio of weft A to weft B is 1:1. The arrangement ratio of 1:1 here means that weft A appears once and weft B appears once, and they are stacked alternately. Among them, the conveying speed of warp A corresponding to the upper structure is S1, the conveying speed of warp A corresponding to the lower structure is S2, and the conveying speed of warp B is S3. S2:S1:S3 is 1.24:1.2:1.

[0027] In one embodiment, material d is prepared. Material d is: 75D / 72F - polyester - semi - dull - DTY - black. Twist 450 turns per meter (450T / S) on material d, and use material d as warp A. Prepare material e. Material e is: 75D / 36F - polyester - semi - dull - DTY. Twist 420 turns per meter on material e, and use the material as warp B. The weft B is: 75D / 72F - polyester - semi - dull - DTY - black. It should be noted that the purpose of twisting the materials above is to twist the yarns together like a twist. This increases the toughness of the materials and replaces the sizing process. It ensures that the weaving process can proceed smoothly and reduces the weaving difficulty of the process.

[0028] In one embodiment, in step S100, the specific production process of weft A includes: Prepare 2 parts of material a. Material a is 150D / 288F - polyester - semi - dull - DTY, and material a is used as the wool - like feeling yarn of the floss. 1 part of material b. Material b is 150D / 96F - polyester semi - dull - DTY - high shrinkage, and material b is used as the core yarn of the wool - like feeling yarn. 1 part of material c. Material c is 150D / 48F - polyester - semi - dull - DTY, and material c is used as the covering yarn of the wool - like feeling yarn. Feed 2 parts of material a, 1 part of material b, and 1 part of material c into the twisting equipment through 4 rollers respectively. Among them, the feeding speed ratio of material a, material b, and material c is 2.17:1:1.15. Specifically, the feeding speed of material a is 56.4m / min, the feeding speed of material b is 26m / min, and the feeding speed of material c is 30m / min.

[0029] Through specific material selection, reasonable combination of material ratios, and reasonable selection of the feeding speed ratio of materials, the present application can produce weft A. Yarn A is a grey yarn of a wool - like yarn, and the fluffiness is similar to that of wool. If the material selection is unreasonable, or the material ratio is unreasonable, or the feeding speed ratio is unreasonable, a good wool - like effect cannot be achieved.

[0030] The method of the present application is introduced in detail through specific embodiments below.

[0031] The method of the present application mainly includes 3 important innovation points. First, the fabric produced by the method of the present application has good light - shielding characteristics, mainly manifested as illuminance E ≤ 180000 lux and no visible light on the reverse side of the fabric. Second, the fabric produced by the method of the present application has good physical resilience performance, the product has good drapability, does not wrinkle, reduces the subsequent processing procedures of the fabric, and saves energy and increases efficiency. Third, the fabric produced by the method of the present application has good woolen texture. The technology disclosed in the present application modifies the physical properties of the materials themselves. By applying the wool - like process of polyester materials, the problem of the application of woolen - texture materials on light - shielding fabrics is solved at the material end and the weaving process.

[0032] To achieve the above effects, the raw materials required for this application include: Material a: 150D / 288F - polyester - semi - dull - DTY; Material b: 150D / 96F - polyester - semi - dull - DTY - high shrinkage; Material c: 150D / 48F - polyester - semi - dull - DTY; Material d: 75D / 72F - polyester - semi - dull - DTY - black; Material e: 75D / 36F - polyester - semi - dull - DTY.

[0033] The equipment required for this application includes: f. A set of air - jet weaving machines with a marking air pressure of 0.55 MPa; g. A warping machine equipped with a set of hydraulic micro - tensioners; h. A set of warp beams, divided into upper, middle, and lower warp beams, with three sets of yarn feeding systems; i. A set of binding - type wrapped - yarn twisting equipment, with the yarn tension controlled by 4 feed rollers; j. A set of doubling - twisting equipment; k. A set of independent warp - yarn tension sensors for the loom; l. A set of dyeing equipment; m. A setting machine.

[0034] The method of this application specifically includes the following steps:

[0035] 1. Preparation of wool - like yarn: Compared with other wool - like / cashmere - like processes that use processes such as air - texturing and sanding, the method of this application is more inclined to innovation in materials and processing methods. Prepare 2 portions of Material a (150D / 288F - polyester - semi - dull - DTY) as the wool - like feeling yarn of the wool - like yarn, 1 portion of Material b (150D / 96F - polyester - semi - dull - DTY - high shrinkage) as the core yarn of the wool - like yarn, and 1 portion of Material c (150D / 48F - polyester - semi - dull - DTY) as the covering yarn of the wool - like yarn. The 2 portions of Material a pass through the 1# roller and 2# roller of the binding - type wrapped - yarn twisting equipment respectively, and the feeding speed of Material a is 56.4 m / min. 1 portion of Material b passes through the 3# roller of the binding - type wrapped - yarn twisting equipment, and the feeding speed of Material b is 26 m / min. 1 portion of Material c passes through the 4# roller of the binding - type wrapped - yarn twisting equipment, and the feeding speed of Material c is 30 m / min. In the preparation process of the above - mentioned wool - like yarn, the feeding speed ratio of the three materials a:b:c = 2.17:1:1.15. This yarn feeding speed ratio is the most suitable spinning ratio obtained through a large number of tests. If the ratio is adjusted, the wool - like effect will not be achieved or the effect will be greatly reduced. Feed the three materials into the rotor of the binding - type wrapped - yarn twisting equipment. Material b is on the innermost side, controlled by the tension. Material a is on the inner side, parallel to Material b, but Material b forms loops naturally as the rotor rotates. Material c is on the outermost side, controlled by the guide hook of the rotor, and performs a revolution movement at 6000 revolutions per minute. Through the above wrapping, the semi - finished yarn of the wool - like yarn, that is, weft yarn A, is formed.

[0036] 2. Prepare material d. Using a doubling twisting machine, add 450 twists per meter to material d to obtain warp yarn A for the fabric. Prepare material e. Using a doubling twisting machine, add 420 twists per meter to material e to obtain warp yarn B for the fabric.

[0037] 3. Warp yarn A is warped by a warping machine into 2 sets of warping beams with 24,000 ends of the same specification, with a width of 360 cm (the upper beam and the middle beam of warping beam h); warp yarn B is warped by a warping machine into 1 set of warping beam with 5,200 ends, with a width of 360 cm (the lower beam of warping beam h).

[0038] 4. After threading the above 3 warping beams, place them on a jet weaving machine. Weave weft yarn A, which is the weft yarn of the fabric, into the front and back of the fabric, that is, the surface layer and the inner layer. Weave material d as weft yarn B of the fabric into the middle layer. The arrangement ratio of weft yarn A to weft yarn B is 1:1, that is, weft yarn A is woven into the upper layer, weft yarn B is woven into the middle layer, weft yarn A is woven into the lower layer, weft yarn B is woven into the middle layer, and the arrangement order is ABAB. The weft density is woven at 48 picks / cm.

[0039] 5. Take the woven grey fabric and dye it through a dyeing machine. The dyeing machine needs to degrease and refine the fabric at a temperature of about 90°C to fully disperse the fibers of the fabric. Before starting the water bath dyeing, determine the surface fluffiness of the degreased and refined fabric. Here, the fluffiness of a cashmere woolen overcoat is used as a reference. Those that do not meet the requirements need to repeat the degreasing and refining. After completing the degreasing and refining, send the fabric into the dyeing machine to start dyeing and disperse coloring. The control method of the dyeing temperature is as follows: in the range of 30°C - 60°C, the heating rate is 2.5°C / min; in the range of 61°C - 110°C, the heating rate is 1.5°C / min; in the range of 111°C - 125°C, the heating rate is 0.8°C / min. The coloring temperature is 125°C, and keep it warm for 55 minutes, then cool down. In the range of 125°C - 30°C, the cooling rate is 2°C / min.

[0040] 6. After completing the dyeing process of the fabric, use a stenter to shape the fabric. The shaping temperature is 175°C to keep the front surface of the fabric flat and the handfeel not too hard. The running speed of the stenter is 16 m / min. Through the preparation of the grey yarn, and then through the water bath dyeing of the dyeing and finishing equipment, the shrinkage characteristics of material b are fully released. Combining with the specific ratio in the spinning process, it can ensure that the fabric has the fluffiness of wool. This kind of fluffiness has more bone and resilience compared with ordinary fluffiness, and has a very high similarity to wool materials. The promotion value of this kind of product is higher, and this kind of material belongs to polyester material, with stronger plasticity. Through post-finishing processes such as steaming, ironing, pressing, printing, and gilding, the additional characteristics of the product can be increased, and the product has higher value.

[0041] Furthermore, in the method of the present application, this weaving structure is also original. In the method of the present application, the fabric is mainly divided into three parts. The upper shaft and the middle shaft of the warp beam h are both made of black materials. The warp yarn A (the warp yarn of the upper shaft of the warp beam h) is interwoven with the weft yarn A and the weft yarn B to form the front and the middle layer of the fabric (a 1.5-layer structure). The warp yarn A (the warp yarn of the middle shaft of the warp beam h) is interwoven with the weft yarn A and the weft yarn B to form the back and the middle layer of the fabric (a 1.5-layer structure). The upper and lower two groups of 1.5-layer fabrics are connected by the warp yarn B (the warp yarn of the lower shaft of the warp beam h) through the binding warp. By the above method, the present application combines the upper and lower two groups of 1.5-layer fabrics of the fabric without using adhesives such as glue, which is environmentally friendly and firm. The fabric structure of the present application is relatively tight. The four layers of weft yarns are tightly combined, and the stresses between them are offset, so it is not easy to wrinkle. The fabric is rich in texture and has good resilience. Moreover, in the method of the present application, the process parameters are set as follows: the warp density is 148 threads / cm, the weft density is 48 threads / cm, the tensions of the three groups of warp beams are respectively set as: 320 N for the upper shaft of the warp beam h, 270 N for the middle shaft of the warp beam h, and 80 N for the lower shaft of the warp beam h. The conveying speed of the warp yarn A corresponding to the upper layer structure (the front and the middle layer of the fabric) is S1, the conveying speed of the warp yarn A corresponding to the lower layer structure (the back and the middle layer of the fabric) is S2, and the conveying speed of the warp yarn B is S3. S2:S1:S3 is 1.24:1.2:1. Through the above differential warp feeding speeds, the front and the middle layer of the fabric of the present application are superimposed, perfectly filling the gaps. The two middle layers are also very tightly combined, blocking the visible light that the front cannot completely block, so that the fabric reaches a light-shielding rate of 99.9999%. The reason why the present application adopts the above weaving method is that the fabric of the present application requires a large number of layers of yarns and is a high weft density product, and the weaving difficulty is relatively large. By using the above method of the present application for weaving, the weaving is relatively smooth, and the weaving efficiency is significantly improved.

[0042] The above embodiments only represent several implementation manners of the present application. The description is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, several modifications and improvements can still be made, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the appended claims.

Claims

1. A manufacturing method of a multi-layer velvet-like light-shielding curtain fabric, characterized in that, Including: S100. Making a grey yarn for imitation wool yarn, using the grey yarn as weft yarn A and making weft yarn B; S200. Making warp yarn A and warp yarn B, where warp yarn A is black; S300. Using the above-mentioned warp yarn A, weft yarn A and weft yarn B to make the upper structure and the lower structure, and using warp yarn B to weave the upper structure and the lower structure together to form a fabric. Among them, the upper structure and the lower structure are connected by the binding warp; It also includes S400. Dyeing the fabric formed in step S300, specifically including: degreasing and refining the fabric at 90°C, and dyeing the fabric after degreasing and refining is completed. The control method of the dyeing temperature is as follows: in the range of 30°C - 60°C, the heating rate is 2.5°C / min; in the range of 61°C - 110°C, the heating rate is 1.5°C / min; in the range of 111°C - 125°C, the heating rate is 0.8°C / min; at a temperature of 125°C, keep warm for 55 minutes, and then cool down. In the range of 125°C - 30°C, the cooling rate is 2°C / min. It also includes S500. Setting the fabric after dyeing in step S400, specifically including: using a setting machine to set the fabric, the setting temperature is 175°C, and the running speed of the setting machine is 16 m / min. In step S300, using the above-mentioned warp yarn A, weft yarn A and weft yarn B to make the upper structure and the lower structure includes: using warp yarn A to weave with weft yarn A and weft yarn B to form the surface layer and the first intermediate layer of the fabric, and the surface layer and the first intermediate layer form the upper structure. Among them, weft yarn A corresponds to the surface layer, and weft yarn B corresponds to the first intermediate layer; Using warp yarn A to weave with weft yarn A and weft yarn B to form the inner layer and the second intermediate layer of the fabric, and the inner layer and the second intermediate layer form the lower structure. Among them, weft yarn A corresponds to the inner layer, and weft yarn B corresponds to the second intermediate layer. The warp density is 148 threads / cm, the weft density is 48 threads / cm, and the arrangement ratio of weft yarn A to weft yarn B is 1:

1. Among them, the conveying speed of warp yarn A corresponding to the upper structure is S1, the conveying speed of warp yarn A corresponding to the lower structure is S2, and the conveying speed of warp yarn B is S3. The ratio of S2:S1:S3 is 1.24:1.2:

1. Preparing material d, where material d is: 75D / 72F - polyester - semi - dull - DTY - black, adding 450 turns per meter to material d, and using material d as warp yarn A; Preparing material e, where material e is: 75D / 36F - polyester - semi - dull - DTY, adding 420 turns per meter to material e, and using material e as warp yarn B. The weft yarn B is: 75D / 72F - polyester - semi - dull - DTY - black. In step S100, the specific production process of the weft yarn A includes: preparing 2 parts of material a, where material a is 150D / 288F - polyester - semi - dull - DTY and is used as the wool - like yarn for the pile yarn, 1 part of material b, where material b is 150D / 96F - polyester - semi - dull - DTY - high - shrinkage and is used as the core yarn of the wool - like yarn, and 1 part of material c, where material c is 150D / 48F - polyester - semi - dull - DTY and is used as the covering yarn of the wool - like yarn. Feed 2 parts of material a, 1 part of material b, and 1 part of material c into the twisting equipment through 4 rollers respectively. Among them, the feeding speed ratio of material a, material b, and material c is 2.17:1:1.

15.

2. The manufacturing method of the multi-layer velvet-like light-shielding curtain fabric according to claim 1, characterized in that The feeding speed of material a is 56.4 m / min, the feeding speed of material b is 26 m / min, and the feeding speed of material c is 30 m / min.

3. A multi-layer velvet blackout curtain fabric, characterized in that: The fabric is made by the method according to claim 1 or 2.