Warp knitted fabric with air structure layer and manufacturing method thereof

Abstract

The present invention provides a warp knitted fabric with an air structure layer and a manufacturing method thereof. The manufacturing method of the warp knitted fabric with an air structure layer comprises providing a plurality of knitting yarns, performing a first sanding step, performing a coating step, performing a warping step, performing a weaving step, and performing a fiber opening step. The sanded knitted yarn is obtained through the first sanding step. The sanded knitted yarn is coated with a water-soluble resin through the coating step to obtain the coated sanded knitted yarn. The coated sanded knitted yarn is subjected to the warping step and the weaving step to obtain a semi-finished fabric, and then the semi-finished fabric is subjected to water-soluble fiber opening and shaping through the fiber opening step to obtain a warp knitted fabric with an air structure layer. The warp knitted fabric with an air structure layer has a plurality of fluffs. Thereby, the warp knitted fabric with an air structure layer can have a fluffy touch and visual effect.

Description

Technical Field

[0001] The invention relates to a warp knitted fabric with an air structure layer and a manufacturing method thereof, in particular to a warp knitted fabric with an air structure layer having a plurality of fluffs and a manufacturing method thereof. Background Art

[0002] Warp knitted air mesh fabric with air structure layer, such as three-layer breathable mesh fabric (commonly known as sandwich fabric), has an air structure layer with good air permeability, so it is widely used in many utensils commonly used in life, such as office chairs, safety helmets, pillows, clothing, backpacks, personal protective gear, etc. However, due to the structural characteristics of the existing three-layer breathable mesh fabric made by warp knitting, it is difficult for its surface to have a velvety touch or velvety visual effect. In addition, the existing three-layer breathable mesh fabric made by warp knitting has a distinct plastic feel, so the comfort of products made by the three-layer breathable mesh fabric made by warp knitting is not good.

[0003] In order to make the surface of the fabric have a velvety feel, the surface of the fabric is traditionally sanded to produce fine velvet on the surface. However, the surface of the three-layer breathable mesh fabric made by warp knitting not only has many different high and low level structures, but also has various complex mesh structures. Therefore, it is impossible to achieve the effect of making the surface of the three-layer breathable mesh fabric have a uniform velvety feel by brushing.

[0004] In addition, if general brushed fibers are used to weave three-layer breathable mesh fabrics in a warp knitting manner, the excessively fast weaving speed of the warp knitting machine will cause a large number of nodes or contamination to be generated in the structure of the three-layer breathable mesh fabrics, thereby significantly reducing the yield rate.

[0005] In summary, developing a warp knitted fabric with an air structure layer and a manufacturing method thereof is a development goal with commercial value. Summary of the invention

[0006] An object of the present invention is to provide a warp knitted fabric with an air structure layer and a method for manufacturing the same, wherein the knitting yarn is sanded and then coated with a water-soluble resin and used to weave a semi-finished fabric. After the semi-finished fabric is woven, it is subjected to water-soluble fiber opening and shaping to obtain a warp knitted fabric with an air structure layer, so as to achieve the goal of giving the warp knitted fabric with an air structure layer a velvety touch and velvety visual effect.

[0007] One aspect of the present invention provides a method for manufacturing a warp knitted fabric with an air structure layer, comprising providing a plurality of knitting yarns, performing a first sanding step, performing a coating step, performing a warping step, performing a weaving step, and performing a fiber opening step. Each knitting yarn is obtained by winding a main core and a plurality of peripheral coating yarns. The first sanding step is to sand the knitting yarn to obtain a plurality of sanded knitting yarns. The coating step is to coat the sanded knitting yarn with a water-soluble resin to obtain a plurality of coated sanded knitting yarns. The warping step is to warp the coated sanded knitting yarn to obtain a plurality of warped yarns. The weaving step is to weave the warped yarns in a warp knitting manner to obtain a semi-finished fabric. The fiber opening step is to perform a water-soluble fiber opening and shaping on the semi-finished fabric to obtain a warp knitted fabric with an air structure layer. The warp knitted fabric with an air structure layer comprises a surface layer, a bottom layer and an inner layer, wherein the inner layer connects the surface layer and the bottom layer, and the surface layer, the bottom layer and the inner layer have a plurality of fluffs.

[0008] According to the aforementioned method for manufacturing the warp knitted fabric with an air structure layer, a second sanding step may be further included, which is to sand an outer surface of the surface layer of the warp knitted fabric with an air structure layer and an outer surface of the bottom layer of the warp knitted fabric with an air structure layer with a sandpaper.

[0009] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, the mesh number of the sandpaper can be less than 400 meshes.

[0010] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, the main core has a denier number range, and the aforementioned denier number range can be 30D to 100D.

[0011] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, each peripheral covering yarn has a denier range and a strand number range, the aforementioned denier range can be 50D to 150D, and the aforementioned strand number range can be 72F to 288F.

[0012] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, the number of the outer covering yarns may be two.

[0013] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, the water-soluble resin can be a water-soluble polyester resin or a water-soluble polyurethane resin.

[0014] According to the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, in the warping step, the coated brushed knitting yarn can be warped in a range of warp numbers, and the aforementioned range of warp numbers can be 100 to 600 per yarn; more preferably, it can be 100 to 300 per yarn.

[0015] Another aspect of the present invention provides a warp knitted fabric with an air structure layer, which is made by the aforementioned method for manufacturing a warp knitted fabric with an air structure layer, wherein the warp knitted fabric with an air structure layer comprises a surface layer, a bottom layer and an inner layer. The inner layer connects the surface layer and the bottom layer. The surface layer, the bottom layer and the inner layer have the fluff.

[0016] Thus, the method for manufacturing the warp knitted fabric with an air structure layer of the present invention can make the warp knitted fabric with an air structure layer have a velvety touch and a velvety visual effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to make the above and other objects, features, advantages and embodiments of the present invention more clearly understood, the accompanying drawings are described as follows:

[0018] Figure 1A is a flowchart showing a method for manufacturing a warp knitted fabric with an air structure layer according to an embodiment of the present invention;

[0019] Figure 1B is a flowchart showing a method for manufacturing a warp knitted fabric with an air structure layer according to another embodiment of the present invention;

[0020] Figure 2 is a side cross-sectional schematic diagram illustrating another aspect of a warp knitted fabric with an air structure layer of the present invention;

[0021] Figure 3A is an enlarged schematic diagram showing the outer surface of a surface layer of a conventional warp knitted fabric with an air structure layer; and

[0022] Figure 3B The figure is an enlarged schematic diagram showing the outer surface of a surface layer of a warp knitted fabric with an air structure layer according to an embodiment of the present invention.

[0023] The reference numerals are described as follows:

[0024] 100, 100a: Method for manufacturing warp knitted fabric with air structure layer

[0025] 110, 110a, 120, 120a, 130, 130a, 140, 140a, 150, 150a, 160, 160a, 170: Step 200: Warp knitted fabric with air structure layer

[0026] 210: Surface

[0027] 211, 221: Outer surface

[0028] 220: Bottom

[0029] 230: Inner layer

[0030] 240: Fluff DETAILED DESCRIPTION

[0031] The following will describe multiple embodiments of the present invention with reference to the drawings. For the purpose of clarity, many practical details will be described together in the following description. However, it should be understood that these practical details should not be used to limit the present invention. That is, in some embodiments of the present invention, these practical details are not necessary. In addition, in order to simplify the drawings, some conventional structures and elements will be illustrated in a simple schematic manner in the drawings; and repeated elements may be represented by the same number.

[0032] Please refer to Figure 1A , Figure 1A The flowchart of the steps of a method 100 for manufacturing a warp knitted fabric with an air structure layer according to an embodiment of the present invention is shown. The method 100 for manufacturing a warp knitted fabric with an air structure layer comprises steps 110, 120, 130, 140, 150 and 160.

[0033] Step 110 is to provide a plurality of braiding yarns. Specifically, each braiding yarn may be obtained by winding a main core and a plurality of peripheral covering yarns, wherein the number of the peripheral covering yarns may be two. More specifically, the main core has a denier range, and the denier range of the main core may be 30D to 100D; each peripheral covering yarn has a denier range and a strand number range, and the denier range of each peripheral covering yarn may be 50D to 150D, and the strand number range of each peripheral covering yarn may be 72F to 288F.

[0034] Step 120 is a first sanding step, which is to sand the braided yarn to obtain a plurality of sanded braided yarns. Specifically, a sanding machine can be used for sanding in step 120, but other equipment or tools that can be used for sanding, such as sandpaper, can also be used in step 120, and the present invention is not limited thereto.

[0035] Step 130 is a coating step, which is to coat the aforementioned brushed knitting yarn with a water-soluble resin to obtain a plurality of coated brushed knitting yarns. Specifically, the aforementioned water-soluble resin can be a water-soluble polyester resin or a water-soluble polyurethane resin, but the present invention is not limited thereto, and other water-soluble resin materials can also be applied to the manufacturing method 100 of the warp knitted fabric with an air structure layer of the present invention.

[0036] Step 140 is to perform a warping step, which is to warp the coated brushed woven yarn to obtain a plurality of warped yarns. In detail, the coated brushed woven yarn can be warped in a range of warp numbers, and the aforementioned range of warp numbers can be 100 to 600 per yarn; more preferably, it can be 100 to 300 per yarn. More specifically, the number of warps in the method 100 for manufacturing a warp knitted fabric with an air structure layer of the present invention cannot be too high to avoid the coated brushed woven yarns from rubbing against each other due to excessive crowding during the warping process, resulting in the water-soluble resin coated on the surface of the coated brushed woven yarn falling off, thereby affecting the subsequent processes.

[0037] In the existing warping step, warping oil needs to be added to reduce the friction during warping and improve the smoothness of warping. However, in step 140, the amount of warping oil used needs to be slightly less than the amount of warping oil used in the existing warping step (about 30% reduction) to avoid affecting the effect of removing the water-soluble resin in the subsequent process.

[0038] Step 150 is a weaving step, which is to weave the warped yarns in a warp knitting manner to obtain a semi-finished fabric. In detail, the weaving steps used in the method 100 for manufacturing a warp knitted fabric with an air structure layer of the present invention are substantially the same as the weaving steps of the existing warp knitted fabric with an air structure layer, and can be adjusted according to the desired fabric use, morphology, size and other factors, so it is not repeated here.

[0039] Step 160 is a fiber opening step, which is to open the semi-finished fabric with water-soluble fiber and shape it to obtain a warp knitted fabric with an air structure layer. In detail, the water-soluble fiber opening is to wash or soak the semi-finished fabric with an aqueous solvent to dissolve the water-soluble resin and expose the fluff on the surface of the semi-finished fabric. After the water-soluble fiber opening is completed, the semi-finished fabric is dried and shaped to obtain the warp knitted fabric with the air structure layer.

[0040] Please refer to Figure 2 , Figure 2 1 is a side cross-sectional schematic diagram of a warp knitted fabric 200 with an air structure layer according to another aspect of the present invention. The warp knitted fabric 200 with an air structure layer comprises a surface layer 210, a bottom layer 220 and an inner layer 230. The inner layer 230 connects the surface layer 210 and the bottom layer 220. Since the surface layer 210, the bottom layer 220 and the inner layer 230 are all semi-finished fabrics woven from the aforementioned warping yarns and shaped after water-soluble fiber opening, the surface layer 210, the bottom layer 220 and the inner layer 230 all have the fluff 240. Thus, the manufacturing method 100 of the warp knitted fabric with an air structure layer according to the present invention can make the warp knitted fabric 200 with an air structure layer have a fluffy touch and a fluffy visual effect.

[0041] Please refer to Figure 1B , Figure 1B 1 is a flow chart showing the steps of a method 100a for manufacturing a warp knitted fabric with an air structure layer according to another embodiment of the present invention. The method 100a for manufacturing a warp knitted fabric with an air structure layer comprises steps 110a, 120a, 130a, 140a, 150a, 160a and 170, wherein steps 110a, 120a, 130a, 140a, 150a and 160a are the same as steps 110, 120, 130, 140, 150 and 160 in the method 100 for manufacturing a warp knitted fabric with an air structure layer according to the aforementioned embodiment, and thus are not further described herein.

[0042] Please refer to Figure 2 Step 170 is a second sanding step, which is to sand an outer surface 211 of the surface layer 210 of the warp knitted fabric 200 with an air structure layer and an outer surface 221 of the bottom layer 220 of the warp knitted fabric 200 with an air structure layer with a sandpaper to enhance the velvety touch and velvety visual effect of the warp knitted fabric 200 with an air structure layer. Specifically, the mesh number of the sandpaper may be less than 400 meshes, but the present invention is not limited thereto.

[0043] Please refer to Figure 3A and Figure 3B , Figure 3A The diagram is an enlarged schematic diagram showing the outer surface of a conventional warp knitted fabric with an air structure layer. Figure 3B FIG. 1 is an enlarged schematic diagram of the outer surface of a warp knitted fabric with an air structure layer according to an embodiment of the present invention. Figure 3A It can be seen that when the warp knitted fabric with an air structure layer is produced with the existing method of producing fluff, such as simply using sanded fibers to weave the warp knitted fabric with an air structure layer or sanding the surface of the warp knitted fabric with an air structure layer, the fluff is not evenly distributed, and many disorderly small fibers and nodes formed by the fibers knotting together are produced in the structure of the existing warp knitted fabric with an air structure layer, thereby blocking the mesh holes for producing a breathable effect, causing the existing warp knitted fabric with an air structure layer to be unsightly in appearance and affecting its use experience and touch.

[0044] On the other hand, by Figure 3B It can be seen that the warp knitted fabric with an air structure layer of the present invention has a neat and beautiful appearance, a clear and obvious mesh structure, and a soft velvety touch and velvety visual effect. Therefore, it can be judged that the warp knitted fabric with an air structure layer of the present invention and the manufacturing method thereof have better performance.

[0045] In summary, the warp knitted fabric with an air structure layer of the present invention and its manufacturing method can be achieved by sanding the knitting yarn and then coating it with a water-soluble resin, and performing water-soluble fiber opening and shaping after the warp knitted fabric with an air structure layer is woven, so as to achieve the goal of making the warp knitted fabric with an air structure layer have a velvety touch and velvety visual effect.

[0046] Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention. Anyone skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the following claims.

Claims

1. A method for manufacturing a warp knitted fabric with an air structure layer, characterized in that: Include: Providing a plurality of braided yarns, wherein each of the braided yarns is obtained by winding a main core and a plurality of peripheral covering yarns; Performing a first sanding step, which is sanding the braided yarn to obtain a plurality of sanded braided yarns; Performing a coating step, which is coating the brushed braided yarn with a water-soluble resin to obtain a plurality of coated brushed braided yarns; Performing a warping step, which is to warp the coated brushed braided yarn to obtain a plurality of warped yarns; Performing a weaving step, in which the warped yarns are woven in a warp knitting manner to obtain a semi-finished fabric; as well as Performing a fiber opening step, which is to perform a water-soluble fiber opening and shaping on the semi-finished fabric to obtain a warp knitted fabric with an air structure layer; The warp knitted fabric with air structure layer has a surface layer, a bottom layer and an inner layer. The inner layer connects the surface layer and the bottom layer, and the surface layer, the bottom layer and the inner layer have a plurality of fluffs.

2. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: Also includes: A second sanding step is performed, which is to sand an outer surface of the surface layer of the warp knitted fabric with an air structure layer and an outer surface of the bottom layer of the warp knitted fabric with an air structure layer with a sandpaper.

3. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 2, characterized in that: The grit of the sandpaper is less than 400 grit.

4. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: The main core has a Denier number range, and the Denier number range is 30D to 100D.

5. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: Each of the outer covering yarns has a denier range and a strand number range, the denier range is 50D to 150D, and the strand number range is 72F to 288F.

6. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: The number of the outer covering yarns is two.

7. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: The water-soluble resin is a water-soluble polyester resin or a water-soluble polyurethane resin.

8. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 1, characterized in that: In the warping step, the coated brushed braided yarn is warped with a warp number range of 100 to 600 warp yarns per yarn.

9. The method for manufacturing a warp knitted fabric with an air structure layer according to claim 8, characterized in that: The number of warping strips ranges from 100 strips / piece to 300 strips / piece.

10. A warp knitted fabric with an air structure layer, characterized in that: The invention is made by the method for manufacturing a warp knitted fabric with an air structure layer according to any one of claims 1 to 9, comprising: the surface layer; the underlying layer; and the inner layer connecting the surface layer and the bottom layer; The surface layer, the bottom layer and the inner layer are provided with the fluff.

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