Preparation method of bed canopy type knitted soft mat based on integrated weaving forming

Abstract

The application relates to a preparation method of a bed canopy type knitted soft mat based on integrated weaving and molding, and relates to the field of textile preparation. The bed canopy type knitted soft mat prepared by the method comprises a soft mat body and a bed canopy. The soft mat body is a three-layer knitted structure, the soft mat body is knitted by using cool yarn and superfine fiber yarn, the bed canopy comprises a bed canopy upper part, a bed canopy lower part, a bed canopy left part and a bed canopy right part, the bed canopy is knitted by using elastic yarn, the soft mat body and the bed canopy are connected through inlaying and loop penetrating, and the bed canopy type knitted soft mat is knitted by using a computerized flat knitting machine. The bed canopy type knitted soft mat is soft in texture, has good moisture absorption, air permeability and heat penetration cooling performance, the bed canopy type mat is integrally knitted and molded, the preparation method is simple, and the bed canopy type mat does not slip during use, so that the above-mentioned technical problems of hard texture of the existing mat, poor moisture absorption and heat dissipation, easy sliding during use and complicated work and the like are solved.

Description

Technical Field

[0001] This application relates to the field of textile preparation technology, and in particular to a method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting molding. Background Technology

[0002] Currently, cooling mats are the most commonly used bedding item to cope with the hot summer environment. The main types of cooling mats on the market include bamboo mats, straw mats, rattan mats, cowhide mats, and ice silk mats. Bamboo mats are cool, but they are hard, have poor moisture absorption and breathability, and are inconvenient to store. Straw mats are softer than bamboo mats, but they are not as cool, are prone to mold, and are difficult to clean. Rattan mats are soft, elastic, and durable, but are difficult to care for and prone to bacterial growth. Cowhide mats have a soft and smooth surface, but are expensive, have poor breathability, and easily accumulate sweat. Ice silk mats are easy to fold and store, absorb moisture, and are durable, but have poor heat dissipation. In addition, cooling mats often slip during use. Current solutions include adding elastic bands at the four corners of the back of the mat to fit over the mattress, or adding fitted sheets around the edges of the mat to cover the mattress.

[0003] Patent CN201332900Y discloses a fitted sheet type cooling mat. The mat's edges are bound, and a cover is attached to the bound edges via a detachable structure using zippers or Velcro. The lower edge of the cover has an elastic rubber adjustment mechanism to ensure the cover fits snugly around the mattress and prevents the mat from slipping. Patent CN206238993U discloses an ice silk cooling mat fitted sheet. It features Velcro fasteners at the lower four corners of the ice silk cooling mat and Velcro at the upper four corners of the fitted sheet, allowing them to be fastened together for a detachable ice silk cooling mat fitted sheet. While these methods can solve the slippage problem during use, they are relatively complex. Summary of the Invention

[0004] The purpose of this application is to provide a method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting. The prepared cooling mat has a soft texture, good moisture absorption, breathability, heat permeability and cooling properties. Moreover, the fitted sheet type cooling mat is one-piece knitted, the preparation method is relatively simple, and there will be no slippage during use. This solves the technical problems of existing cooling mats such as hard texture, poor moisture absorption and heat dissipation, easy slippage during use, and complicated workmanship.

[0005] To achieve the above objectives, the technical solution adopted in this application is as follows: A method for preparing a fitted sheet knitted cooling mat based on one-piece knitting, the fitted sheet knitted cooling mat based on one-piece knitting includes a cooling mat body and a fitted sheet. The cooling mat body has a three-layer knitted structure and is woven from cooling yarn and microfiber yarn. The fitted sheet includes an upper fitted sheet, a lower fitted sheet, a left fitted sheet, and a right fitted sheet and is woven from elastic yarn. The cooling mat body and the fitted sheet are connected by intarsia and loop stitching. The fitted sheet knitted cooling mat based on one-piece knitting is knitted by a computerized flat knitting machine. The method includes: S1. The yarn feeder a drives the elastic yarn to the right to start weaving. The number of rows in the first horizontal row is less than the number of rows in the soft mat body. Both ends simultaneously increase stitches in a step-like manner to weave back and forth until we weave to the left until the number of rows is equal to the number of rows in the soft mat body plus the number of rows in the left and right parts of the fitted sheet, thus forming the lower part of the fitted sheet. S2. Yarn tip a drives the elastic yarn to weave to the right in the weaving area on the left side of the fitted sheet, and stops weaving at the connection between the left side of the fitted sheet and the soft cooling mat body. Next, yarn tip b drives the cooling yarn and yarn tip c drives the microfiber yarn to weave to the right in the weaving area on the soft cooling mat body, and stops weaving at the connection between the soft cooling mat body and the right side of the fitted sheet. Then, yarn tip d drives the elastic yarn to weave to the right in the weaving area on the right side of the fitted sheet until this horizontal row is completed. Then, weaving back and forth is performed until the left side of the fitted sheet, the right side of the fitted sheet, and the soft cooling mat body are completed to the left. S3. The yarn feeder a drives the elastic yarn to the right to weave. The number of warp rows in the first horizontal row is equal to the number of warp rows of the soft cooling mat body plus the number of warp rows of the left and right sides of the fitted sheet. Both ends simultaneously decrease stitches back and forth in a stepped manner until the warp rows are woven to the left until the number of warp rows is equal to the number of warp rows of the first horizontal row of the lower part of the fitted sheet, forming the upper part of the fitted sheet symmetrical to the lower part of the fitted sheet, and finally obtaining the fitted sheet knitted soft cooling mat based on one-piece knitting.

[0006] In one possible implementation, the soft cooling mat body includes an upper cooling mat body and a lower cooling mat body, the upper cooling mat body and the lower cooling mat body are connected by an intermediate cooling mat body layer, the upper cooling mat body is the skin-contacting surface, the lower cooling mat body is the non-skin-contacting surface, and the intermediate cooling mat body layer is a connecting layer.

[0007] In one possible implementation, the upper layer of the cooling mat body is the process front, which is woven from cooling yarn.

[0008] In one possible implementation, the lower layer of the cooling mat body is the reverse side, woven from microfiber yarn.

[0009] In one possible implementation, the middle layer of the cooling mat body is woven from microfiber yarn.

[0010] In one possible implementation, the cooling yarn is ultra-high molecular weight polyethylene (UHMWPE), the microfiber yarn is ultra-fine polyester (DTY), and the elastic yarn is nylon-spandex coated yarn.

[0011] In one possible implementation, coarse capillaries are formed between the fibers of the ultra-high molecular weight polyethylene (UHMWPE) in the upper layer of the cooling mat body, and fine capillaries are formed between the fibers of the ultra-fine polyester (DTY) in the lower layer of the cooling mat body, so that a differential capillary effect is formed between the three layers of the soft cooling mat body.

[0012] In one possible implementation, the upper and lower parts of the fitted sheet are connected to the soft cooling mat body by means of a coil loop.

[0013] In one possible implementation, the left and right portions of the fitted sheet are connected to the soft cooling mat body by an inlay technique.

[0014] In one possible implementation, the left and right sides of the fitted sheet are woven with float yarn, so that the length of the left and right sides of the fitted sheet after unraveling is less than the length of the main body of the soft cooling mat.

[0015] The beneficial effects of the technical solution provided in this application include at least the following: The soft cooling mat in this application has a stable structure and a soft texture, with perforated surfaces on both sides, giving it good breathability. The upper layer of the mat's ultra-high molecular weight polyethylene (UHMWPE) fibers forms relatively large capillaries, while the lower layer's ultra-fine polyester (DTY) fibers form relatively fine capillaries, creating a strong differential capillary effect across the three layers, resulting in excellent unidirectional moisture wicking properties. The upper layer (skin-contact surface) is woven solely from cooling yarn, namely UHMWPE. The relatively flat surface allows for a larger contact area between the skin and the fabric, resulting in excellent cooling properties. This fitted sheet knitted cooling mat, based on a one-piece knitting process, is woven in one piece on a computerized flat knitting machine, eliminating the need for subsequent processing and sewing. The manufacturing process is simple. Furthermore, the lengths of the left and right sides of the fitted sheet are shorter than the length of the main body of the cooling mat, and the widths at the upper and lower edges of the fitted sheet are smaller than the width of the main body of the cooling mat. The elastic yarn used in the fitted sheet has a larger shrinkage rate than the yarn used in the main body of the cooling mat, ensuring that the designed fitted sheet knitted cooling mat can firmly cover the mattress and will not slip during use. Attached Figure Description

[0016] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings: Figure 1 This invention provides a schematic diagram of the structure of a fitted sheet knitted soft cooling mat based on an exemplary embodiment of the present application. Figure 2 This invention provides a schematic diagram of the structure of a soft cooling mat body based on an integrally woven fitted sheet knitted soft cooling mat according to an exemplary embodiment of the present application. Figure 3 This illustration shows a schematic diagram of the unfolded deformation of a fitted sheet knitted soft cooling mat based on an exemplary embodiment of this application; Figure 4 The illustration shows a weaving process diagram of a fitted sheet type knitted soft cooling mat based on one-piece knitting, provided by an exemplary embodiment of this application. Detailed Implementation

[0017] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0018] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0019] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0020] Figure 1 This application shows a schematic diagram of the structure of a fitted sheet type soft cooling mat based on an exemplary embodiment of the present application. The fitted sheet type soft cooling mat includes a soft cooling mat body 1 and a fitted sheet 2. The soft cooling mat body 1 is a three-layer knitted structure.

[0021] Specifically, please refer to Figure 2 The soft cooling mat body 1 includes an upper cooling mat body 5 and a lower cooling mat body 6, which are connected by a middle cooling mat body layer 7. The upper cooling mat body 5 is the skin-contacting surface, the lower cooling mat body 6 is the non-skin-contacting surface, and the middle cooling mat body layer 7 is the connecting layer. Specifically, the upper cooling mat body 5 is the processing front side, woven with cooling yarn; the lower cooling mat body 6 is the processing back side, woven with microfiber yarn; and the middle cooling mat body layer 7 is also woven with microfiber yarn. In this embodiment, the cooling yarn is ultra-high molecular weight polyethylene (UHMWPE), and the microfiber yarn is microfiber polyester (DTY).

[0022] It is worth noting that, please refer to Figure 2 The upper layer 5 of the cooling mat body has coarser capillaries between the fibers of ultra-high molecular weight polyethylene (UHMWPE), while the lower layer 6 of the cooling mat body has finer capillaries between the fibers of ultra-fine polyester (DTY). This creates a differential capillary effect between the three layers of the soft cooling mat body 1, guiding the sweat 4 on the skin surface 3 to flow spontaneously from the upper layer 5 of the cooling mat body to the lower layer 6, giving the fabric excellent one-way moisture-wicking properties.

[0023] Furthermore, to achieve a one-piece knitted molding, the fitted sheet knitted soft cooling mat has been unfolded and deformed as shown below. Please refer to [link / reference]. Figure 3 The fitted sheet 2 includes an upper fitted sheet 24, a lower fitted sheet 21, a left fitted sheet 22, and a right fitted sheet 23, and is woven from elastic yarn. In this embodiment, the elastic yarn is nylon-spandex covered yarn. The soft cooling mat body 1 and the fitted sheet 2 are connected by intarsia and loop fastening. Specifically, the upper fitted sheet 24 and the lower fitted sheet 21 are connected to the soft cooling mat body 1 by loop fastening; the left fitted sheet 22 and the right fitted sheet 23 are connected to the soft cooling mat body 1 by intarsia.

[0024] It should be noted that the left and right sides of the fitted sheet 22 and 23 are woven with float yarn, so that the length of the left and right sides of the fitted sheet 22 and 23 after unraveling is less than the length of the main body of the soft cooling mat 1.

[0025] In detail, the aforementioned fitted sheet knitted soft cooling mat, based on a one-piece knitting process, is woven using a computerized flat knitting machine. Please refer to [link / reference needed]. Figure 3The upper part 24, lower part 21, and left part 22 of the fitted sheet, i.e., polygons DG′′G′H′H′′E′′E′F′F′′A, are continuously woven using a single yarn feeder. The main body 1 of the soft mat, i.e., quadrilateral ABCD, is continuously woven using two yarn feeders. The right part 23 of the fitted sheet, i.e., quadrilateral BCG′′F′′, is continuously woven using a single yarn feeder. The lower part 21, upper part 24, and main body 1 of the fitted sheet are connected by looping stitches, while the left part 22, right part 23, and main body 1 of the soft mat are connected by inlay stitch (i.e., loop weaving).

[0026] Figure 4 The illustration shows a weaving process diagram of a fitted sheet knitted soft cooling mat based on an exemplary embodiment of this application. The preparation method of the fitted sheet knitted soft cooling mat based on an exemplary embodiment of this application specifically includes the following steps: Step S1: The yarn feeder a drives the elastic yarn - nylon-spandex covered yarn to the right to start weaving a four-line weave. The number of warp rows in the first horizontal row is less than the number of warp rows in the soft mat body 1. The two ends simultaneously increase stitches in a step-like manner and weave back and forth until we weave to the left until the number of warp rows is equal to the number of warp rows in the soft mat body 1 plus the number of warp rows in the left part 22 and the right part 23 of the fitted sheet, forming the lower part 21 of the fitted sheet. Step S2: Turn the needles to the front needle bed. Yarn feeder a continues to drive the elastic yarn – nylon-spandex covered yarn – to the right within the knitting area of ​​the left side 22 of the fitted sheet, stopping at the connection point between the left side 22 of the fitted sheet and the soft cooling mat body 1. Next, yarn feeder b drives the cooling yarn – ultra-high molecular weight polyethylene (UHMWPE), and yarn feeder c drives the microfiber yarn – microfiber polyester (DTY) – to the right within the knitting area of ​​the soft cooling mat body 1, stopping at the connection point between the soft cooling mat body 1 and the right side 23 of the fitted sheet. Then, yarn feeder d drives the elastic yarn – nylon-spandex covered yarn… The covering yarn is woven to the right in the knitting area of ​​the right side 23 of the fitted sheet until this row is completed. Then, it is woven back and forth until the left side 22 of the fitted sheet, the soft mat body 1, and the right side 23 of the fitted sheet are completed. Among them, when the yarn feeders a and d are knitting the left side 22 and the right side 23 of the fitted sheet respectively, the floating yarn is used reasonably to make the length of the left side 22 and the right side 23 of the fitted sheet shrink to be larger than that of the soft mat body 1. Yarn feeder b is knitted in loops on the front needle bed, and yarn feeder c is knitted in loops on the back needle bed and knitted in a skipped loop and a tucked loop on the front needle bed. Step S3: The yarn feeder a continues to drive the elastic yarn - nylon-spandex covered yarn to the right for weaving. The number of warp rows in the first horizontal row is equal to the number of warp rows of the soft mat body 1 plus the number of warp rows of the left and right fitted sheet 22. The two ends simultaneously decrease stitches back and forth in a stepped manner until the number of warp rows is equal to the number of warp rows in the first horizontal row of the lower fitted sheet 21, forming the upper fitted sheet 24 symmetrical to the lower fitted sheet 21, and finally obtaining a fitted sheet knitted soft mat based on one-piece knitting.

[0027] Performance testing: The following is a performance comparison between the soft cooling mat body of the fitted sheet knitted soft cooling mat based on one-piece knitting provided in this application and two types of cooling mats (straw mats and rattan mats) on the existing market.

[0028] (1) Softness (the smaller the bending length, the smaller the bending stiffness, and the better the softness of the fabric) (2) Moisture absorption and wicking performance (when the immersion time of the upper layer, the immersion time of the lower layer, the water absorption rate of the upper layer, the water absorption rate of the lower layer, and the unidirectional transfer index all reach level 3 or above, the fabric has good moisture absorption and wicking performance) (3) Air permeability and moisture permeability (the higher the air permeability, the better the air permeability of the fabric; the higher the moisture permeability, the better the moisture permeability of the fabric). (4) Cooling performance (the lower the thermal resistance, clo value, and heat retention rate, the larger the heat transfer coefficient, and the better the cooling performance of the fabric) In summary, the soft cooling mat of this application has a stable structure, a soft texture, and a perforated appearance on both sides, giving it good breathability. The upper layer of the mat's ultra-high molecular weight polyethylene (UHMWPE) fibers forms relatively large capillaries, while the lower layer's ultra-fine polyester (DTY) fibers form relatively fine capillaries, creating a strong differential capillary effect between the three layers of the soft cooling mat, resulting in excellent unidirectional moisture-wicking properties. The upper layer (skin-contact surface) of the mat is woven solely from cooling yarn, namely ultra-high molecular weight polyethylene (UHMWPE). The surface is relatively flat, resulting in a larger contact area between the skin and the fabric, providing excellent cooling properties. This fitted sheet knitted cooling mat, based on a one-piece knitting process, is woven in one piece on a computerized flat knitting machine, eliminating the need for subsequent processing and sewing, thus simplifying the manufacturing process. Furthermore, the lengths of the left and right sides of the fitted sheet are shorter than the length of the main body of the cooling mat, and the widths at the upper and lower edges of the fitted sheet are smaller than the width of the main body of the cooling mat. The elastic yarn used in the fitted sheet has a larger shrinkage rate than the yarn used in the main body of the cooling mat, ensuring that the designed fitted sheet knitted cooling mat can firmly cover the mattress without slipping during use.

[0029] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting molding, characterized in that, The integrated knitted fitted sheet cooling mat includes a cooling mat body and a fitted sheet. The cooling mat body has a three-layer knitted structure, woven from cooling yarn and microfiber yarn. The cooling yarn is ultra-high molecular weight polyethylene (UHMWPE), and the microfiber yarn is ultra-fine polyester (DTY). The cooling mat body includes an upper layer and a lower layer, connected by an intermediate layer. The UHMWPE fibers in the upper layer form coarse capillaries, while the microfiber fibers in the lower layer form fine capillaries. The fitted sheet includes an upper part, a lower part, a left part, and a right part. The fitted sheet is woven from elastic yarn. The soft cooling mat body is connected to the fitted sheet via intarsia and loop stitching. This one-piece knitted soft cooling mat is woven using a computerized flat knitting machine. The lengths of the left and right parts of the fitted sheet are less than the length of the soft cooling mat body, and the width at the edges of the upper and lower parts of the fitted sheet is less than the width of the soft cooling mat body. The method includes: S1. The yarn feeder a drives the elastic yarn to the right to start weaving. The number of rows in the first horizontal row is less than the number of rows in the soft mat body. Both ends simultaneously increase stitches in a step-like manner to weave back and forth until we weave to the left until the number of rows is equal to the number of rows in the soft mat body plus the number of rows in the left and right parts of the fitted sheet, thus forming the lower part of the fitted sheet. S2. Yarn tip a drives the elastic yarn to weave to the right in the weaving area on the left side of the fitted sheet, and stops weaving at the connection between the left side of the fitted sheet and the soft cooling mat body. Next, yarn tip b drives the cooling yarn and yarn tip c drives the microfiber yarn to weave to the right in the weaving area on the soft cooling mat body, and stops weaving at the connection between the soft cooling mat body and the right side of the fitted sheet. Then, yarn tip d drives the elastic yarn to weave to the right in the weaving area on the right side of the fitted sheet until this horizontal row is completed. Then, weaving back and forth is performed until the left side of the fitted sheet, the right side of the fitted sheet, and the soft cooling mat body are completed to the left. S3. The yarn feeder a drives the elastic yarn to the right to weave. The number of warp rows in the first horizontal row is equal to the number of warp rows of the soft cooling mat body plus the number of warp rows of the left and right sides of the fitted sheet. Both ends simultaneously decrease stitches back and forth in a stepped manner until the warp rows are woven to the left until the number of warp rows is equal to the number of warp rows of the first horizontal row of the lower part of the fitted sheet, forming the upper part of the fitted sheet symmetrical to the lower part of the fitted sheet, and finally obtaining the fitted sheet knitted soft cooling mat based on one-piece knitting.

2. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 1, characterized in that, The upper layer of the cooling mat body is the skin-contacting surface, the lower layer of the cooling mat body is the non-skin-contacting surface, and the middle layer of the cooling mat body is the connecting layer.

3. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 2, characterized in that, The upper layer of the cooling mat body is the front side, which is woven from cooling yarn.

4. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 2, characterized in that, The lower layer of the mat body is the reverse side, woven from microfiber yarn.

5. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 2, characterized in that, The middle layer of the mat is made of microfiber yarn.

6. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 2, characterized in that, The elastic yarn is nylon-spandex coated yarn.

7. The method for preparing a fitted sheet type knitted soft cooling mat based on integral knitting as described in claim 6, characterized in that, The three-layer structure of the soft cooling mat body forms a differential capillary effect, and both sides of the soft cooling mat body have a perforated structure.

8. The method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting as described in any one of claims 1 to 7, characterized in that, The upper and lower parts of the fitted sheet are connected to the main body of the soft cooling mat by means of a coil loop.

9. The method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting as described in any one of claims 1 to 7, characterized in that, The left and right sides of the fitted sheet are connected to the main body of the soft cooling mat by an inlay pattern.

10. The method for preparing a fitted sheet type knitted soft cooling mat based on one-piece knitting according to any one of claims 1 to 7, characterized in that, The left and right sides of the fitted sheet are woven with float yarn.

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