A cut-resistant and dyeable knitted elastic fabric and its processing method

Abstract

The present invention provides a cut-resistant and dyeable knitted stretch fabric and a processing method. The method comprises the following steps: first, by changing the double-sided tissue structure, a four-layer composite structure is formed, namely, an upper fabric layer, an intermediate connecting layer, an anti-cut layer, and a lower fabric layer; wherein, the upper fabric layer and the lower fabric layer are composed of nylon and spandex; the intermediate connecting layer is composed of nylon, connecting the upper and lower layers together; the anti-cut layer is inlaid between the upper and lower fabric layers in the form of floating threads without loops by ultra-strong polyethylene yarn. Secondly, the fabric is rolled before dyeing and pre-shrinked. Then, it is taken out of the vat without unwinding, the positions of the inner and outer baffles are readjusted, and then it is put into the vat for dyeing. Finally, it is stretched, softened, and dried. The dyeable knitted stretch fabric provided by the present invention has excellent cut-resistant performance, good elasticity, can be dyed or printed, has small color difference after dyeing, and feels soft and is comfortable to wear. It is suitable for ski suits, diving suits, mountaineering suits, fencing suits, outdoor training suits and other fields.

Description

Technical Field

[0001] The present invention relates to the technical field of textile fabric production, in particular to a cut-resistant and dyeable knitted stretch fabric and a processing method thereof. Background Art

[0002] As living standards improve, exercise has become a new fashion. Whether it's professional short-track speed skating or enthusiasts engaging in deep-sea diving, mountaineering, fencing, or outdoor training, critical parts of the body, such as the chest, shoulders, arms, and legs, are vulnerable to punctures and cuts from sharp objects, which can be life-threatening. Therefore, developing protective clothing fabrics to protect sports health is crucial.

[0003] Traditional protective clothing materials are mainly the following:

[0004] First, high-performance alloys are cold-rolled to form an integral stab-proof vest, or high-strength and lightweight metal materials (such as aluminum alloy) are used to make a protective layer similar to scale armor. Although this material has excellent protective performance, its weight and rigidity have great restrictions and impacts on the user's activities and wearing comfort.

[0005] Second, twisting metal wires into rings or winding them into metal loops, then laminating them with fabric or other protective materials, or forming lightweight metal sheets into shaped composite layers. Protective clothing produced in this way is still heavy, uncomfortable, and not washable, making it difficult to weave and produce.

[0006] Third, aramid fiber is used as raw material. However, aramid is relatively expensive, has a high glass transition temperature, and poor dyeability. It is currently mainly used in the fields of aerospace or military equipment.

[0007] Fourth, it is produced using high-strength, high-modulus polyethylene fiber as raw material. High-strength, high-modulus polyethylene fiber is one of the strongest synthetic fibers currently in industrial use. In addition to its high strength and modulus, it also boasts lightweight, low density, impact resistance, and cut resistance. However, its drawbacks are that it cannot be dyed, is not heat-resistant, and has a melting point of 130-150°C, making the dyeing and finishing of fabrics very difficult. Furthermore, if the fiber comes into direct contact with the skin, wearing comfort is very poor.

[0008] Chinese invention patent application publication number CN105155097A discloses a method for producing cut-resistant fabric made of ultra-high molecular weight polyethylene staple yarn. Specifically, the method utilizes a weaving process, with both warp and weft yarns made entirely of ultra-high molecular weight polyethylene staple yarn. The fabric produced by this method is composed entirely of polyethylene fibers and cannot be dyed. Furthermore, the weaving method produces a dense, thick texture, resulting in poor wear comfort.

[0009] A Chinese utility model patent with publication number CN212242479U discloses an ultra-high molecular weight polyethylene composite fabric. Specifically, the fabric body is a laminated fabric, including a nylon surface layer and an ultra-high molecular weight polyethylene inner layer, with a low-melting-point membrane disposed between the nylon surface layer and the ultra-high molecular weight polyethylene inner layer. The nylon surface layer is woven with nylon 66 as the warp and weft yarns, using a 5-weft satin weave, while the ultra-high molecular weight polyethylene inner layer is woven with 75D ultra-high molecular weight polyethylene filaments as the warp and weft yarns, using a plain weave. Although the fabric prepared by this method can solve the dyeing and printing problems of the nylon surface layer, the polyethylene inner layer cannot be dyed or printed. In addition, the fabric is thick, dense, and inelastic, and the polyethylene inner layer is fixed with a low-melting-point membrane, resulting in poor air permeability and discomfort.

[0010] Chinese invention patent application publication number CN114941199A discloses a protective knitted fabric for ice and snow sports. Specifically, it features a six-mode sandwich structure. Protective yarn and elastic backing yarn are looped by the upper needle disc to form the protective surface layer, while the clothing yarn and elastic backing yarn are looped by the lower needle cylinder to form the clothing inner layer. Connecting yarn is simultaneously tucked by the upper and lower needle cylinders to form the connecting layer. This fabric, produced using this method, utilizes highly elastic semi-gloss nylon DTY for the clothing layer and ultra-strong polyethylene fiber for the protective layer. While this method improves wearer comfort, the protective surface layer cannot be dyed or printed, limiting its applicability.

[0011] A Chinese invention patent application, publication number CN114134607A, discloses a highly elastic, cut-resistant composite yarn, a preparation method thereof, and a cut-resistant fabric containing the composite yarn. Specifically, the highly elastic, cut-resistant composite yarn is obtained by spirally twisting the UHMWPE filaments with the spandex filaments as the axial direction using spandex filaments. Furthermore, a three-thread weft-knitted sweater is knitted to resemble a fish scale weave. The face yarn is a plain weave of nylon filaments, the base yarn is a plain weave of nylon and spandex filaments, and the added yarn is a padding weave with UHMWPE filaments as the sheath yarn and spandex filaments as the core yarn. During weaving, the face yarn is attached to the upper layer to facilitate dyeing or printing. The resulting fabric can only be dyed or printed on one side, and the bottom layer of the fabric has a fish scale-like texture. The UHMWPE filaments in the bottom layer come into direct contact with the skin, making it very uncomfortable to wear. Furthermore, the curling and hemming problems also affect the sewing performance of the fabric. Summary of the Invention

[0012] Based on this, in order to solve the problem that the above-mentioned existing protective fabrics are difficult to coordinate cut resistance, dyeability and wearing comfort in actual production, the present invention provides a cut-resistant and dyeable knitted stretch fabric and a processing method, the specific technical solution of which is as follows:

[0013] On the one hand, the present invention provides a cut-resistant, dyeable knitted stretch fabric. By varying the weft-knitted double-sided weave structure, it forms a four-layer composite structure: an upper fabric layer, a middle connecting layer, a cut-resistant layer, and a lower fabric layer. The upper and lower fabric layers are composed of nylon and spandex yarns, ensuring excellent comfort, elasticity, and dyeability. The middle connecting layer is composed of nylon yarn, connecting the upper and lower layers. The cut-resistant layer is composed of super-strong polyethylene yarn, embedded between the upper and lower layers in a floating, non-looped manner, forming a sandwich structure. This layer forms a physical anchor with the middle connecting layer to prevent slippage and ensure excellent cut-resistant performance. This four-layer structure systematically addresses the fabric's cut-resistant properties, dyeability, and wearing comfort. Furthermore, the cut-resistant layer's super-strong polyethylene yarn is embedded between the upper and lower layers in a floating, non-looped manner, forming a physical anchor with the middle connecting layer to prevent slippage and ensure the fabric's cut-resistant properties and breathability.

[0014] Furthermore, the nylon yarns in the upper and lower fabric layers are fiber filaments or staple yarns, and the yarn D number is 30D to 150D; the spandex yarns are fiber filaments, and the yarn D number is 20D to 100D.

[0015] Furthermore, the nylon yarn of the intermediate connecting layer is fiber filament or staple yarn, and the yarn D number is 5D to 80D.

[0016] Furthermore, the super-strong polyethylene yarn is a fiber filament or a staple yarn, the yarn D number is 50D to 400D, and the yarn strength is greater than 30cN / dtex.

[0017] Furthermore, the nylon yarn in the upper and lower layers of the fabric is replaced with other dyeable yarns, and the dyeable yarn is one of polyester yarn, cotton yarn, and linen yarn; or / and the spandex yarn in the upper and lower layers of the fabric is replaced with other elastic fiber yarns, and the elastic fiber yarn is polyetherester elastic fiber yarn or T400 elastic fiber yarn; or / and the yarn in the middle connecting layer is the same or different type as the yarn in the upper and lower layers of the fabric body; or / and the super-strong polyethylene yarn in the anti-cut layer is replaced with aramid yarn or metal fiber yarn.

[0018] Furthermore, the fabric body can pass the EN 388 cut resistance level 3 test, with elastic elongation and elastic recovery ≥ 70%, and the color difference between the inner and outer layers after dyeing CMC DE ≤ 0.5, and the color difference between the edge and the center CMC DE ≤ 0.3.

[0019] The cut-resistant and dyeable knitted stretch fabric provided by the present invention can be processed not only by dyeing but also by printing.

[0020] On the other hand, the present invention also provides a method for processing a cut-resistant and dyeable knitted stretch fabric, comprising the following steps:

[0021] Four layers of composite grey fabric are formed by weaving yarns;

[0022] The woven grey fabric is rolled up before dyeing and pre-shrinked;

[0023] In the above method, preferably, the pre-shrinkage pretreatment temperature is 80°C to 105°C, the time is 10 min to 60 min, the bath ratio is 1:5 to 1:50, and the pre-treatment additives are: FK-9516 degreaser 1g to 4g / L, soda ash 0.5g to 5g / L.

[0024] Take the pre-shrinked fabric out of the dyeing drum without unwinding it. Readjust the position of the inner and outer baffles according to the shrinkage degree of the fabric on the dyeing drum to prevent the dye from overflowing from the shrinkage space on the edge of the dyeing drum and affecting the dyeing uniformity.

[0025] Push the dyeing shaft cylinder with the inner and outer baffles readjusted into the dyeing vat again for dyeing;

[0026] The dyed fabric is stretched, softened and dried to obtain the finished fabric.

[0027] In the above method, preferably, the drying temperature is 80° C. to 150° C., and the drying time is 10s to 200s.

[0028] The present invention provides a method for processing cut-resistant, dyeable knitted stretch fabric. By rolling and pre-shrinking the fabric before dyeing, the fabric is fully shrunk while removing oil and impurities. Because high-strength polyethylene fibers are not heat-resistant, the fabric cannot be initially shaped at high temperatures. Therefore, the present invention pre-shrinks the fabric on a dyeing drum to fully shrink it. The fabric is then removed from the dyeing drum, and the positions of the inner and outer baffles are readjusted based on the degree of shrinkage before it is re-entered into the dyeing drum for dyeing. This prevents further shrinkage during the dyeing process, which can lead to color differences between the edges and the center, and between the inner and outer layers. The fabric dyed using this method can pass the EN 388 cut-resistant performance level 3 test, with elastic elongation and elastic recovery ≥70%, and a color difference (CMC DE) of ≤0.5 between the inner and outer layers after dyeing, and a color difference (CMC DE) of ≤0.3 between the edges and the center. The fabric is soft, comfortable, and breathable. It can also be dyed or printed with vibrant colors and rich patterns. This fabric can be used in ski wear, diving suits, mountaineering wear, fencing wear, outdoor training wear, bulletproof clothing, and other fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but rather the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate corresponding parts.

[0030] Figure 13 is a schematic structural diagram of a cut-resistant and dyeable knitted stretch fabric according to an embodiment of the present invention.

[0031] Description of reference numerals:

[0032] 1- Upper fabric layer; 2- Middle connecting layer; 3- Anti-cutting layer; 4- Lower fabric layer. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with its embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and do not limit the scope of protection of the present invention.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] like Figure 1 As shown, a cut-resistant and dyeable knitted stretch fabric in one embodiment of the present invention forms a fabric body with a four-layer composite structure through changes in the weft-knitted double-sided tissue structure; the fabric body includes a fabric upper layer 1, an intermediate connecting layer 2, an anti-cut layer 3 and a fabric lower layer 4, and the fabric upper layer 1 and the fabric lower layer 4 are composed of nylon yarn and spandex yarn, ensuring excellent comfort, elasticity and dyeability; the intermediate connecting layer 2 is composed of nylon yarn, connecting the fabric upper layer 1 and the fabric lower layer 4 together; the anti-cut layer 3 is composed of super-strong polyethylene yarn in the form of floating line without loops, and is embedded between the fabric upper layer 1 and the fabric lower layer 4 to form a wire structure, and the wire structure forms a physical fixed point with the intermediate connecting layer 2 to prevent it from slipping, ensuring excellent cut-resistant performance; the fabric body is dyed after weaving is completed.

[0036] Example 1

[0037] In a specific embodiment, the present invention forms a complete pattern with 2 needles and 5 yarns, and the knitting structure is:

[0038] The first route adopts a structure in which all the knitting needles of the needle disc are in a loop and all the knitting needles of the needle cylinder are not knitting, and constitutes the upper layer of the fabric of the present invention. The upper layer of the fabric body is made of 50D / 24F high elastic semi-gloss nylon DTY and 20D spandex.

[0039] The second route adopts a structure in which all the knitting needles of the needle cylinder form a loop and all the knitting needles of the needle disk do not knit, forming the lower layer of the fabric of the present invention. The lower layer of the fabric body is made of 40D / 36F high elastic semi-gloss nylon DTY and 20D spandex.

[0040] The third route adopts the needle dial to tuck the odd-numbered needles and not knit the even-numbered needles, and the needle cylinder to not knit the odd-numbered needles and tuck the even-numbered needles, forming one of the middle connecting layers of the fabric of the present invention.

[0041] The fourth route adopts the needle dial with odd-numbered needles not knitted and even-numbered needles tucked, and the needle cylinder with odd-numbered needles tucked and even-numbered needles not knitted, constituting the second middle connecting layer of the fabric of the present invention.

[0042] The middle connecting layer of the 3rd and 4th routes is made of 8D / 5F nylon filament round yarn.

[0043] The fifth route uses a needle disc and a needle cylinder where all needles are not knitting. The cut-resistant yarn is interwoven between the upper and lower layers in the form of floating yarn without loops. The cut-resistant yarn is made of 75D / 30F super-strong polyethylene fiber yarn.

[0044] After the yarn is woven and the fabric is obtained, it is rolled before dyeing and pre-shrinked. Specifically, the pre-shrinkage temperature is 105°C, the time is 20 minutes, the bath ratio is 1:25, and the pre-treatment additives are: FK-9516 degreaser 2g / L, soda ash 2g / L. This ensures the pre-shrinkage treatment is effective and allows for full shrinkage.

[0045] After pre-shrinkage, the dye shaft is removed from the dye vat without unwinding. The inner and outer baffles are repositioned to prevent dye from spilling out of the shrinkage space at the sides of the dye shaft, which could affect dyeing uniformity. The dye shaft is then reinserted into the dye vat and dyeing proceeds. The dyeing temperature is 98°C and the dyeing time is 45 minutes. This prevents further shrinkage during the dyeing process, which could lead to color differences between the edges and the inner and outer layers.

[0046] After dyeing, tentering, softening and drying are carried out at a temperature of 120°C and a speed of 10 m / min.

[0047] The fabric was sent to a third party for testing, and the anti-cutting performance test was as follows:

[0048]

[0049] The comprehensive assessment of anti-cutting performance can reach level 3 standards.

[0050] Fabric tensile properties test is as follows:

[0051]

[0052] Fabric color difference test is as follows:

[0053] Taking the dyeing shaft surface fabric as the standard, the color difference of the shaft bottom fabric CMC DE is 0.47, and the color difference of the inner and outer layers meets the internal control standard CMC DE≤0.5;

[0054] Taking the middle section of the dyeing shaft as the standard, the color difference of the left section of the fabric is CMC DE 0.27, and the color difference of the right section of the fabric is CMCDE 0.29. The color difference between the edge and the center meets the internal control standard CMC DE ≤ 0.3;

[0055] Taking the middle section of the fabric at the bottom of the dyeing shaft as the standard, the color difference of the left section of the fabric is CMC DE 0.24, and the color difference of the right section of the fabric is CMCDE 0.28. The color difference between the edge and the center meets the internal control standard CMC DE≤0.3.

[0056] Example 2

[0057] In another specific embodiment, the present invention forms a complete pattern with 2 needles and 5 yarns, and the knitting structure is:

[0058] The first route adopts a structure in which all the knitting needles of the needle disc form a loop and all the knitting needles of the needle cylinder do not knit, forming the upper layer of the fabric of the present invention. The upper layer of the fabric body is made of 68D / 68F matte nylon ATY and 40D spandex.

[0059] The second route adopts a structure in which all the knitting needles of the needle cylinder form a loop and all the knitting needles of the needle disk do not knit, forming the lower layer of the fabric of the present invention. The lower layer of the fabric body is made of 68D / 68F matte nylon ATY and 40D spandex.

[0060] The third route adopts the needle dial to tuck the odd-numbered needles and not knit the even-numbered needles, and the needle cylinder to not knit the odd-numbered needles and tuck the even-numbered needles, forming one of the middle connecting layers of the fabric of the present invention.

[0061] The fourth route adopts the needle dial with odd-numbered needles not knitted and even-numbered needles tucked, and the needle cylinder with odd-numbered needles tucked and even-numbered needles not knitted, constituting the second middle connecting layer of the fabric of the present invention.

[0062] The middle connecting layer of the 3rd and 4th routes is made of 20D / 24F nylon high elastic semi-gloss yarn.

[0063] The fifth route uses a needle disc and a needle cylinder where all needles are not knitting. The cut-resistant yarn is interwoven between the upper and lower layers in the form of floating yarn without loops. The cut-resistant yarn is made of 100D / 66F super-strong polyethylene fiber.

[0064] After the yarn is woven to obtain the fabric body, the fabric body is printed, and then steamed and washed with water at a steaming temperature of 105° C. for 3 minutes and a washing temperature of 80° C. for 5 minutes.

[0065] Finally, stretch, soften and dry at 120℃ and 10m / min.

[0066] The fabric was sent to a third party for testing, and the anti-cutting performance test was as follows:

[0067]

[0068] The comprehensive assessment of anti-cutting performance can reach level 3 standards.

[0069] Fabric tensile properties test is as follows:

[0070]

[0071] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0072] The above embodiments merely illustrate several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make various modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A cut-resistant and dyeable knitted stretch fabric, characterized in that: By changing the weft-knitted double-sided structure, a fabric body with a four-layer composite structure is formed; the fabric body comprises a fabric upper layer (1), an intermediate connecting layer (2), an anti-cutting layer (3) and a fabric lower layer (4); the fabric upper layer (1) and the fabric lower layer (4) are composed of nylon yarn and spandex yarn, ensuring excellent comfort, elasticity and dyeability; the intermediate connecting layer (2) is composed of nylon yarn, connecting the fabric upper layer (1) and the fabric lower layer (4) together; the anti-cutting layer (3) is composed of super-strong polyethylene yarn in the form of floating thread and no loop, and is embedded between the fabric upper layer (1) and the fabric lower layer (4) to form a wire-interlaced structure; the wire-interlaced structure forms a physical fixed point with the intermediate connecting layer (2) to prevent it from slipping, thereby ensuring excellent anti-cutting performance; after the weaving is completed, the fabric body is dyed; The nylon yarns in the upper fabric layer (1) and the lower fabric layer (4) are fiber filaments or staple yarns, and the yarn D number is 30D to 150D; the spandex yarns are fiber filaments, and the yarn D number is 20D to 100D; The super-strong polyethylene yarn is a fiber filament or a staple yarn, the yarn D number is 50D to 400D, and the yarn strength is greater than 30cN / dtex.

2. The cut-resistant and dyeable knitted stretch fabric according to claim 1, characterized in that: The nylon yarn of the intermediate connecting layer (2) is a fiber filament or a staple yarn, and the yarn D number is 5D to 80D.

3. The cut-resistant and dyeable knitted stretch fabric according to claim 1, characterized in that: The nylon yarn in the upper fabric layer (1) and the lower fabric layer (4) is replaced with other dyeable yarns, wherein the dyeable yarn is one of polyester yarn, cotton yarn and linen yarn; or / and Replacing the spandex yarn in the upper fabric layer (1) and the lower fabric layer (4) with other elastic fiber yarns, wherein the elastic fiber yarns are polyetherester elastic fiber yarns or T400 elastic fiber yarns; or / and The yarns of the intermediate connecting layer (2) are of the same or different type as the yarns of the upper and lower layers of the fabric body; or / and The super strong polyethylene yarn of the cut-resistant layer (3) is replaced with aramid yarn or metal fiber yarn.

4. The cut-resistant and dyeable knitted stretch fabric according to claim 1, characterized in that: The dyed fabric can pass the EN 388 cut resistance level 3 test, with elastic elongation and elastic recovery ≥ 70%, and the color difference CMC DE of the inner and outer layers after dyeing is ≤ 0.5, and the color difference CMC DE of the edge and center is ≤ 0.

3.

5. The cut-resistant and dyeable knitted stretch fabric according to claim 1, characterized in that: After the fabric body is woven, the dyeing process is replaced by a printing process.

6. A method for processing a cut-resistant and dyeable knitted stretch fabric, applied to the cut-resistant and dyeable knitted stretch fabric according to any one of claims 1 to 5, characterized in that: The following steps are involved: Four layers of composite grey fabric are formed by weaving yarns; The woven grey fabric is rolled before dyeing and pre-shrinked; Take the pre-shrinked fabric out of the dyeing drum without unwinding it. Readjust the position of the inner and outer baffles according to the shrinkage degree of the fabric on the dyeing drum to prevent the dye from overflowing from the shrinkage space on the edge of the dyeing drum and affecting the dyeing uniformity. Push the dye shaft cylinder with the inner and outer baffles readjusted into the dye vat again for dyeing; The dyed fabric is stretched, softened and dried to obtain the finished fabric.

7. The method for processing cut-resistant and dyeable knitted stretch fabric according to claim 6, characterized in that: The pre-shrinkage pretreatment temperature is 80° C. to 105° C., the time is 10 min to 60 min, the bath ratio is 1:5 to 1:50, and the pre-treatment additives are: FK-9516 degreaser 1 g to 4 g / L, and soda ash 0.5 g to 5 g / L.

8. The method for processing cut-resistant and dyeable knitted stretch fabric according to claim 7, characterized in that: In the steps of stretching, softening and drying the dyed fabric, the drying temperature is 80° C. to 150° C., and the drying time is 10s to 200s.

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