Novel warm tricot flannel and manufacturing method thereof

Abstract

The application discloses a novel warm warp-knitted blanket and a manufacturing method thereof, and belongs to the field of textile technology. The novel warm warp-knitted blanket comprises a blanket body which is integrally woven by a warp knitting machine, and at least part of yarns of the blanket body are aerogel yarns.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and more specifically, to a novel warm warp-knitted fleece fabric and its manufacturing method. Background Technology

[0002] As we all know, air is the best thermal insulation material; for example, the loft of down is an important standard for judging its quality. Similarly, fleece fabric, which is a layer of air insulation formed on the surface of woven fabric through yarn brushing or loop weaving, reduces the thermal conductivity of the fabric by the fluff or loops on the surface, thus achieving the effect of keeping warm.

[0003] However, in actual use, consumers will find that after long-term contact between the fabric and the body, the plush or loops are compressed and compacted, rendering the fluffy plush or loops ineffective and losing their function of using air to reduce the thermal conductivity and keep warm.

[0004] Aerogel is the lightest known solid material in the world. Because its interior is mostly gas, it appears as a cloud or mist, hence the name "solid smoke." Aerogel is currently the lightest and best-insulating material known in the world, possessing properties such as ultra-lightweight, extremely low thermal conductivity, high thermal stability, sound insulation, fire resistance, and environmental friendliness.

[0005] Therefore, combining aerogel with traditional fleece will achieve better heat retention performance. Summary of the Invention

[0006] To address the technical problem of the aforementioned velvet fabric's inability to provide stable warmth, this invention provides a novel warm warp-knitted velvet fabric and its manufacturing method.

[0007] This invention discloses a novel type of warm warp-knitted fleece fabric.

[0008] A novel warm warp-knitted fleece fabric comprises a fleece body woven integrally by a warp knitting machine using yarn warp combing, wherein at least a portion of the yarn woven into the fleece body is aerogel yarn.

[0009] Preferably, the fleece body also includes a surface layer, a middle layer, and a fleece layer.

[0010] Preferably, the surface layer and the intermediate layer are entirely woven from aerogel yarn.

[0011] Preferably, at least a portion of the yarns constituting the plush layer are aerogel yarns, and another portion are hot melt yarns.

[0012] Preferably, a jacquard layer is also provided on the surface layer.

[0013] This invention also discloses a method for manufacturing a novel warm warp-knitted fleece fabric.

[0014] A method for producing a novel warm warp-knitted fleece fabric includes:

[0015] Comb setup: Use a patterned warp knitting machine with at least three ground combs for weaving;

[0016] Comb and thread the yarn: After the yarn is warped, it is threaded onto the ground comb according to the weaving process. The warped yarn includes aerogel yarn.

[0017] Flannel weaving: Using at least one ground comb to weave a warp knitting chain structure on the front needle bed to form the surface layer of the velvet body; using at least two ground combs to weave back and forth between the front and back needle beds, using a warp knitting variation warp satin structure to form the middle layer and pile layer of the velvet body.

[0018] Preferably, at least two combs are used to comb the surface layer for jacquard weaving to form a jacquard layer;

[0019] Preferably, the warped yarn also includes heat-fused yarn, and the heat-fused yarn is heat-fused in certain areas of the pile layer and the intermediate layer, making certain areas of the pile layer more raised.

[0020] By adopting the above technical solution, the beneficial effects of the present invention are:

[0021] 1. Compared with existing technologies, this solution applies aerogel yarn to the weaving process of warp-knitted fleece. The aerogel yarn is filled with nano-air clusters, maintaining the characteristic that more than 90% of the aerogel is air. It also retains the extremely low thermal conductivity of aerogel (≤0.02W / (MK)) which far exceeds the national standard. This extends the warmth-retaining function of the fleece from the pile layer to the surface layer of the basic fleece body, improving the warmth-retaining efficiency. At the same time, the warmth-retaining effect of the pile layer will not be lost even after the pile layer is compacted during use.

[0022] 2. Compared with existing technologies, this solution adds hot melt yarn during the weaving process of the plush layer. The inherent rigidity of the hot melt yarn supports the plush layer and prevents it from collapsing and compacting, thereby improving the heat retention performance.

[0023] 3. Compared with existing technologies, the aerogel yarn fiber used in this solution has a much larger specific surface area than porous hollow microfiber. While having good moisture absorption and air permeability, it is also more convenient for downstream dyeing and printing processes, saving production costs in subsequent dyeing and finishing. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one or more embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on such drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the fleece body structure of the present invention;

[0026] Figure 2 This is a cross-sectional view of the fleece body of the present invention;

[0027] Figure 3 This is a diagram of the weaving structure of the present invention;

[0028] Key reference numerals: 1. Fleece body; 2. Surface layer; 3. Middle layer; 4. Plush layer; 5. Jacquard; 6. Aerogel yarn; 7. Hot melt yarn. Implementation

[0029] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings and examples, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. It should be noted that, as long as there is no conflict, the various embodiments and features in the various embodiments of the present invention can be combined with each other, and the resulting technical solutions are all within the protection scope of the present invention.

[0030] Furthermore, numerous specific details are set forth in the following description for illustrative purposes to provide a thorough understanding of the embodiments of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without the specific details or particular methods described herein.

[0031] [A novel warm warp-knitted fleece fabric provided by the present invention]

[0032] A novel warm warp-knitted fleece fabric includes a fleece body 1 woven integrally by a comb-knitting machine, wherein at least a portion of the yarns used to weave the fleece body 1 are aerogel yarns 6. The fleece body 1 also includes a face layer 2, a middle layer 3, and a pile layer 4. The face layer 2, middle layer 3, and pile layer 4 can be entirely woven from aerogel yarns 6, or they can be woven from a mixture of aerogel yarns 6 and other yarns. To make the pile layer 4 more stable, heat-fused yarns 7 are added during the weaving process of the fleece body 1, and these yarns are heat-fused to the middle layer 3 and the pile layer 4, making certain areas of the pile layer 4 more raised and stable.

[0033] To enhance the aesthetics of the velvet body 1, jacquard 5 can be applied to the surface layer 2 using the comb bar of the comb knitting machine.

[0034] [A novel method for manufacturing warm warp-knitted fleece fabric according to the present invention]

[0035] A method for producing a novel warm warp-knitted fleece fabric includes:

[0036] Comb setup: Select a patterned warp knitting machine with at least three ground combs for weaving. At the same time, in order to meet the requirements of jacquard 5 process, the patterned combs can be configured according to the process requirements.

[0037] Comb and thread the yarn: After the yarn is warped, it is threaded on the ground comb according to the weaving process. The warped yarn includes aerogel yarn 6.

[0038] Flannel weaving: Using at least one ground comb, the fabric is knitted on the front needle bed to form the surface layer 2 of the fabric body 1. To improve the texture of the surface layer 2, more ground combs can be used. Using at least two ground combs, the fabric is knitted back and forth between the front and back needle beds, using a warp-knitted variation warp pile structure. Some ground combs knit in loops from the front needle bed to the back needle bed to form the middle layer 3, while some ground combs knit in loops on the front needle bed but not on the back needle bed to form the pile layer 4 of the fabric body 1.

[0039] To enhance the aesthetics of the velvet body 1, at least two combs are used to apply a warp-knitted jacquard 5 structure to the surface layer 2, forming a jacquard 5 layer on the surface layer 2.

[0040] To improve the stability and raised feel of the plush layer 4, hot melt yarn is added during warping and threaded onto the comb bar. It is then woven back and forth between the front and back needle beds. After weaving, the plush fabric body 1 is partially heat-fused in a directional manner. Example 1

[0041] Reference Figures 1-3 This invention provides a novel warm warp-knitted fleece fabric, comprising a fleece body 1 woven integrally by a patterned warp knitting machine, wherein at least a portion of the yarns woven into the fleece body 1 are aerogel yarns 6. The fleece body 1 also includes a surface layer 2, a middle layer 3, and a pile layer 4, all woven from aerogel yarns 6. To make the pile layer 4 more stable, heat-fused yarns 7 are added during the weaving process of the fleece body 1, and heat-fused between the middle layer 3 and the pile layer 4, making certain areas of the pile layer 4 more raised and stable. Furthermore, to enhance the aesthetics of the fleece body 1, jacquard weaving 5 can be applied to the surface layer 2 using the patterned comb of the patterned warp knitting machine.

[0042] S1. Comb setting: A patterned comb warp knitting machine is selected for weaving. This patterned comb warp knitting machine uses seven combs for weaving, namely the first patterned comb (patterned comb 1), the second patterned comb (patterned comb 2), the third ground comb (GB3), the fourth ground comb (GB4), the fifth ground comb (GB5), the sixth ground comb (GB6), and the seventh ground comb (GB7).

[0043] S2. Yarn threading for combs: GB4 and GB5 use a 1-thread-1-skip method, which means threading one yarn and then skipping one needle position, and repeating this cycle to thread through all the needle positions of the comb. GB3, GB6, and GB7 use a full-thread method.

[0044] S3, Mesh weaving:

[0045] Flower comb 1: Colored yarn SCY-P-FDY150D / 48F*2 polyester double-wrapped yarn;

[0046] Flower Comb 2: SCY-N-FDY150D / 36F*2 Nylon Hot Melt Yarn (Empty Package 0219#) / P-DTY150D / 48F CD Bright White Low Elastic Lightweight Mesh Double-Covered Yarn;

[0047] Surface layer 2 weave:

[0048] GB3: Warped P-DTY100D / 48F semi-glossy aerogel fiber low-elasticity lightweight mesh, 6 warp heads, 512 yarns per warp head, gear feed rate 1900mm / lactage, running chain weave 1-0 / 0-0 / 0-1 / 1-1 / / , GB3 aerogel fiber yarn content is about 21.965%;

[0049] GB4: Warped P-DTY100D / 48F semi-glossy aerogel fiber low-elasticity lightweight mesh, 6 warp heads, 256 yarns per warp head, gear feed rate 2100mm / lacquer, variable warp plain weave 0-1 / 1-1 / 2-1 / 1-1 / / , GB4 aerogel fiber yarn content is about 12.139%;

[0050] GB5: Warped P-DTY100D / 48F semi-glossy aerogel fiber low-elasticity lightweight mesh, 6 warp heads, 256 yarns per warp head, gear feed rate 2100mm / lacquer, variable warp plain weave 0-1 / 1-1 / 2-1 / 1-1 / / , GB5 aerogel fiber yarn content approximately 12.139%;

[0051] Those skilled in the art should understand that the thickness and texture of the surface layer 2 can be changed by adding 1 to 3 comb bars.

[0052] The weaving of the middle layer 3 and the plush layer 4:

[0053] GB6: Warped P-DTY100D / 48F semi-glossy aerogel fiber low-elasticity lightweight mesh, 6 warp heads, 476 yarns per warp head, gear feed rate 3800m / lacquer, variable warp satin weave 2-3 / 4-5 / 3-2 / 1-0 / / , GB6 aerogel fiber yarn content approximately 26.879%;

[0054] GB7: Warped P-DTY100D / 48F semi-glossy aerogel fiber low-elasticity lightweight mesh, 6 warp heads, each with 476 yarns. GB7 yarns are threaded onto the machine in a full-thread manner, with a gear feed rate of 3800m / lacquer. The weave is a variable warp satin structure of 3-2 / 1-0 / 2-3 / 4-5 / / . The content of GB7 aerogel fiber yarn is approximately 26.879%. Example 2

[0055] Reference Figures 1-3 This invention provides a novel warm warp-knitted fleece fabric, comprising a fleece body 1 woven integrally by a patterned warp knitting machine, wherein at least a portion of the yarns woven into the fleece body 1 are aerogel yarns 6. The fleece body 1 also includes a surface layer 2, a middle layer 3, and a pile layer 4, wherein the surface layer 2, middle layer 3, and pile layer 4 are partly woven from aerogel yarns 6 and partly from other yarns. To make the pile layer 4 more stable, heat-fused yarns 7 are added during the weaving process of the fleece body 1, and heat-fused between the middle layer 3 and the pile layer 4, making certain areas of the pile layer 4 more raised and stable. Furthermore, to enhance the aesthetics of the fleece body 1, jacquard weaving 5 can be applied to the surface layer 2 using the patterned comb of the patterned warp knitting machine.

[0056] S1. Comb setting: A patterned comb warp knitting machine is selected for weaving. This patterned comb warp knitting machine uses seven combs for weaving, namely the first patterned comb (patterned comb 1), the second patterned comb (patterned comb 2), the third ground comb (GB3), the fourth ground comb (GB4), the fifth ground comb (GB5), the sixth ground comb (GB6), and the seventh ground comb (GB7).

[0057] S2. Yarn threading for combs: GB4 and GB5 use a 1-thread-1-skip method, which means threading one yarn and then skipping one needle position, and repeating this cycle to thread through all the needle positions of the comb. GB3, GB6, and GB7 use a full-thread method.

[0058] S3, Mesh weaving:

[0059] Flower Comb 1: Colored yarn P-SCY-1MM seven-color cylindrical rope;

[0060] Flower Comb 2: SCY-N-FDY150D / 48F*2 polyester hot melt yarn / P-DTY200D / 96F environmentally friendly bright white low elastic lightweight mesh double-wrapped yarn;

[0061] Surface layer 2 weave:

[0062] GB3: Warping P-DTY100D / 96F high-strength polyester low-elasticity lightweight mesh, 6 warp heads, 512 yarns per warp head, gear feed rate 1950mm / lacquer, running chain weave 1-0 / 0-0 / 0-1 / 1-1 / / , GB3 high-strength polyester yarn content is about 20.708%;

[0063] GB4: Warping P-DTY100D / 96F high-strength polyester low-elasticity lightweight mesh, 6 warp heads, 256 yarns per warp head, gear feed rate 2180mm / lacquer, variable warp plain weave 0-1 / 1-1 / 2-1 / 1-1 / / , GB4 high-strength polyester yarn content accounts for about 11.444%;

[0064] GB5: Warped P-DTY100D / 96F high-strength polyester low-elasticity lightweight mesh, 6 warp heads, 256 yarns per warp head, gear feed rate 2180mm / lacquer, variable warp plain weave 0-1 / 1-1 / 2-1 / 1-1 / / , GB5 high-strength polyester yarn content is about 11.444%;

[0065] Those skilled in the art should understand that the thickness and texture of the surface layer 2 can be changed by adding 1 to 3 comb bars.

[0066] The weaving of the middle layer 3 and the plush layer 4:

[0067] GB6: Warping P-DTY75D / 48F aerogel fiber yarn, 6 warp heads, 476 yarns per warp head, gear feed rate 3850m / lacquer, variable warp satin weave 1-0 / 1-1 / 0-1 / 2-1 / / / , GB6 aerogel fiber yarn content is about 31.063%;

[0068] GB7: Warping P-DTY75D / 48F aerogel fiber yarn, 6 warp heads, 476 yarns per warp head, gear feed rate 3175m / lacquer, variable warp satin weave 1-1 / 1-0 / 0-1 / 1-1 / / , GB7 aerogel fiber yarn content accounts for about 25.341%.

[0069] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A novel warm warp-knitted fleece fabric, comprising a fleece fabric body woven integrally from yarn using a warp knitting machine, characterized in that: At least a portion of the yarn woven into the fleece body is aerogel yarn. The fleece body also includes a face layer, an intermediate layer, and a pile layer. The intermediate layer is formed by at least two ground combs running back and forth between the front and back needle beds in a warp-knitted satin structure. The at least one ground comb used to knit the intermediate layer forms loops on the front needle bed but not loops on the back needle bed to form the pile layer.

2. The novel warm-insulating warp-knitted fleece fabric according to claim 1, characterized in that: The top and middle layers are woven from aerogel yarns.

3. The novel warm-insulating warp-knitted fleece fabric according to claim 2, characterized in that: At least a portion of the yarns that make up the plush layer are aerogel yarns.

4. The novel warm-insulating warp-knitted fleece fabric according to any one of claims 1 to 3, characterized in that: A jacquard layer is also provided on the surface.

5. A method for manufacturing a novel warm warp-knitted fleece fabric, characterized in that: include: Comb setup: Use a patterned warp knitting machine with at least three ground combs for weaving; Comb and thread the yarn: After the yarn is warped, it is threaded onto the ground comb according to the weaving process. The warped yarn includes aerogel yarn. Flannel weaving: Using at least one ground comb, a warp knitting chain is used to weave on the front needle bed to form the surface layer of the velvet body; using at least two ground combs, a warp knitting variation warp satin structure is used to weave back and forth between the front and back needle beds, wherein at least one ground comb weaves in loops from the front needle bed to the back needle bed to form the middle layer, and at least one ground comb weaves in loops on the front needle bed but not on the back needle bed to form the pile layer of the velvet body.

6. The manufacturing method according to claim 5, characterized in that: Use at least two combs to weave jacquard patterns on the surface layer to form a jacquard layer.

7. The manufacturing method according to claim 5, characterized in that: Warped yarns also include heat-melting yarns.

8. The manufacturing method according to claim 6, characterized in that: The yarn in the comb-and-thread frame also includes heat-melting yarn.

9. The manufacturing method according to claim 7 or 8, characterized in that: The heat-melting yarn is then heat-melted in certain areas of the plush layer and the intermediate layer, making those areas of the plush layer more raised.

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