Polyester grey fabric and preparation process thereof

Abstract

The application discloses a polyester gray cloth and a preparation process thereof, relates to the technical field of textiles, and aims to solve the problem that noise reduction and comfort cannot be simultaneously considered for the polyester gray cloth, and the technical scheme is as follows: the polyester gray cloth comprises an outer layer, the outer layer is sequentially and fixedly connected with a noise reduction layer and an inner layer, a plurality of ventilation grooves are arranged on the surfaces of the noise reduction layer and the outer layer, and the outer layer is fixedly connected with a shock absorption area with increasing pores along with vibration at the ventilation grooves.The outer layer of the polyester gray cloth and the preparation process thereof are made of polyester profiled cross-section fibers and carbon fibers, and the polyester profiled cross-section fibers have a fluffy hand feeling, so that people feel comfortable when touching the outer layer.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and more specifically, to a polyester grey fabric and its preparation process. Background Technology

[0002] Polyester greige fabric, also known as polyester cloth, is the most common type of greige fabric made from chemical fibers in my country. Among them, greige fabric made from polyester fibers is called polyester greige fabric. Polyester greige fabric has many advantages, such as high strength, good elasticity, good heat resistance, good water absorption, and good abrasion resistance, which makes it applicable to various fields of life.

[0003] Chinese Patent No. CN1 03895275A discloses a sound-absorbing and noise-reducing curtain fabric. Its key technical features are: a surface sound-absorbing layer, a middle waterproof layer, and a fabric substrate. The middle waterproof layer is disposed on the upper surface of the fabric substrate, the surface sound-absorbing layer is disposed on the upper surface of the middle waterproof layer, the surface sound-absorbing layer is a colored sound-absorbing coating, the middle waterproof layer is made of PVC film or waterproof coating, and the fabric substrate is made of polyester fiber and linen fiber blended in a certain proportion.

[0004] The above solution involves creating a fabric with a sound-absorbing layer, an intermediate waterproof layer, and a fabric matrix. This fabric has a good noise reduction effect. However, the solution does not take into account that modern soundproof rooms often use polyester fabric on the walls to enhance the sound insulation effect. In the traditional use of polyester fabric, the fabric is quite thick, which makes it stiff and rigid. Workers would lean against the fabric, which is uncomfortable because of its stiffness. Therefore, modern polyester fabric presents a problem where noise reduction and comfort are difficult to balance.

[0005] Therefore, a new solution is needed to address this problem. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a polyester greige fabric and its preparation process.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution: the polyester fabric and its preparation process include an outer layer, wherein a noise reduction layer and an inner layer are fixedly connected to the outer layer in sequence, and a plurality of ventilation grooves are opened on the surface of the noise reduction layer and the outer layer, and a shock-absorbing zone with increasing pore size as it vibrates is fixedly connected to the outer layer located at the ventilation groove.

[0008] The present invention is further configured such that: the damping zone includes a first damping layer and a second damping layer, the first damping layer is fixedly connected to the side away from the inner layer, and the elasticity of the second damping layer is greater than that of the first damping layer.

[0009] The present invention is further configured such that: a plurality of first through holes are formed on the surface of the first damping layer, and a plurality of second through holes are formed on the surface of the second damping layer, wherein the first through holes and the second through holes are staggered.

[0010] The invention is further configured such that: the noise reduction layer located on both sides of the ventilation slot is provided with guide slots, and the guide slots are connected to the ventilation slots.

[0011] The invention is further configured such that the noise reduction layer located in the guide groove is fixedly connected with a number of fluff fibers.

[0012] The invention is further configured such that: the outer layer is woven from buffer yarn, the buffer yarn is formed by twisting polyester profiled cross-section fibers and carbon fibers, and the cross-sectional shape of the polyester profiled cross-section fibers is triangular.

[0013] The invention is further configured such that: the noise reduction layer is woven from noise reduction yarn, the noise reduction yarn includes a yarn core and a covering layer located outside the yarn core, the yarn core is formed by twisting spandex fiber and polyester fiber, the covering layer is formed by twisting polyester fiber and carbon fiber, and the covering layer is spirally wound around the outside of the yarn core.

[0014] The invention is further configured such that: the inner layer is woven from abrasion-resistant yarn, and the abrasion-resistant yarn is formed by twisting several polyester fibers.

[0015] The invention is further configured such that: the damping zone is a double-layer structure, the surface structure of the double-layer structure is 10 pages with the warp float as floating and the weft float as sinking, and the structure cycle of the surface structure of the double-layer structure from left to right and from bottom to top is: sinking-float-sinking-float-sinking-float-sinking-float-sinking-float, floating-float-float-float-sinking-sinking-sinking-sinking-sinking-sinking-sinking, sinking-float-sinking-float-sinking-float-sinking-sinking-sinking, sinking-float-sinking-float-sinking-float-sinking-sinking-sinking, sinking-float-float-float-sinking-float-sinking-sinking-sinking-sinking-sinking-sinking-s The double-layered structure has 6 heddles and its warp yarns are floating, while the weft yarns of the double-layered structure are sinking. The double-layered structure repeats as follows: floating, sinking, floating, sinking, sinking, floating ...

[0016] The present invention is further configured as follows: a process for preparing polyester grey fabric, including,

[0017] Step 1: Weaving, using a shuttle loom to weave the outer layer, noise reduction layer, and inner layer separately;

[0018] Step 2: Cutting. Using a cutting machine, ventilation grooves are cut out on the noise reduction layer, and then guide grooves are hot-pressed out.

[0019] Step 3: Preliminary stitching, using a sewing machine to sew the inner layer and the noise reduction layer together;

[0020] Step 4: Flocking, which is performed using a flocking machine in the guide groove;

[0021] Step 5: Final shaping. The inner layer, noise reduction layer, and outer layer are sewn together using a sewing machine, and then post-processing is performed.

[0022] In summary, the present invention has the following beneficial effects:

[0023] When a person uses a soundproof room, the sound-generating device inside emits sound, which is transmitted to the outer layer. The pores in the outer layer act as a damping agent. Some of the sound passes through the damping zone and then into the noise-reducing layer. Because the sound causes airflow, the airflow exerts a force on the first and second damping layers, causing them to deform. Since the elasticity of the second damping layer is greater than that of the first, the second through-hole on the second damping layer deforms more than the first through-hole. After deformation, the first and second through-holes become larger, increasing the amount of air passing through them. At the same time, the first and second damping layers are further apart. The air passing through the first and second through-holes is guided by the guide grooves and flows into the pile, which further enhances the noise-reducing effect of the noise-reducing layer.

[0024] When the soundproof room is not in use, the first and second damping layers return to their initial shapes. Because the first and second through holes are misaligned, the contact area between the first and second damping layers and the air is increased, giving the damping zone a good dustproof effect. This means that when there is sound, the first and second damping layers deform, thereby increasing the amount of air passing through the first and second through holes. Then, noise reduction is achieved through the fleece, inner layer, and noise reduction layer. When there is no sound, the first and second damping layers return to their original shape, giving them even better dustproof performance. Attached Figure Description

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

[0026] Figure 2 for Figure 1 Enlarged view of point A in the middle;

[0027] Figure 3 Cross-sectional view of the present invention Figure 1 ;

[0028] Figure 4 Cross-sectional view of the present invention Figure 2 ;

[0029] Figure 5 for Figure 4 Enlarged view of point B in the middle;

[0030] Figure 6 This is a slice diagram of the cushioning yarn;

[0031] Figure 7 This is a slice image of the noise-reducing yarn;

[0032] Figure 8 This is a slice image of the abrasion-resistant yarn;

[0033] Figure 9 A tissue diagram of a two-layered structure;

[0034] Figure 10 This is a tissue diagram of a double-layered inner tissue.

[0035] In the diagram: 1. Outer layer; 2. Noise reduction layer; 3. Inner layer; 4. Ventilation slot; 5. First shock-absorbing layer; 6. Second shock-absorbing layer; 7. First through hole; 8. Second through hole; 9. Guide slot; 10. Fleece; 11. Buffer yarn; 12. Polyester profiled cross-section fiber; 13. Carbon fiber; 14. Noise-reducing yarn; 15. Yarn core; 16. Covering layer; 17. Spandex fiber; 18. Polyester fiber; 19. Abrasion-resistant yarn. Detailed Implementation

[0036] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0037] The polyester greige fabric, such as Figures 1 to 3As shown, the system includes an outer layer 1, to which a noise-reducing layer 2 and an inner layer 3 are fixedly connected. The polyester fabric is fixed to the wall of the soundproof room. Sound waves from the sound-generating device are transmitted to the outer layer 1. Because the fabric is woven from yarns, gaps are formed between the yarns, allowing air to enter the polyester fabric through these gaps. Several ventilation slots 4 are provided on the surfaces of both the noise-reducing layer 2 and the outer layer 1. Sound is generated by vibration and can propagate through the air, ultimately reaching the outer layer 1 and then being transmitted into the polyester fabric through the gaps in the outer layer 1. The outer layer 1 acts as a vibration buffer, thus providing excellent noise reduction characteristics. The outer layer 1, located at the ventilation slots 4, is fixedly connected to a noise-reducing layer 2 and an inner layer 3 that vibrate with the sound. The increased porosity of the damping zone, distributed on the outer layer 1, allows sound to be transmitted to it. This damping zone is composed of two layers of fabric, creating pores. Vibration causes airflow, allowing air to reach the damping zone and deform it. This deformation increases the pore size of the damping zone, increasing the rate at which air enters the polyester fabric. When the polyester fabric is touched, the ventilation slots 4 and the damping zone reduce the overall structural strength of the fabric, resulting in a comfortable feel. Furthermore, when a person leans against the polyester fabric, its enhanced breathability provides a comfortable sensation of wind on their back.

[0038] like Figure 1 , Figure 4 , Figure 5 , Figure 9 and Figure 10As shown, the damping zone includes a first damping layer 5 and a second damping layer 6. The first damping layer 5 is fixedly connected to the side away from the inner layer 3 and is integrally formed on the outer layer 1. The first damping layer 5 is formed during the weaving process of the outer layer 1. The elasticity of the second damping layer 6 is greater than that of the first damping layer 5, the weaving density of the second damping layer 6 is less than that of the first damping layer 5, and the yarn elasticity of the second damping layer 6 is greater than that of the yarn in the second damping layer 6. The damping zone is designed with a double-layer structure. The surface structure of the double-layer structure is 10 heddles with the warp float being float and the weft float being sink. The structure cycle of the surface structure of the double-layer structure from left to right and from bottom to top is: sink-float sink-float-float-float-float-float-float-float, float-float-float-float-float-float-float-float-float, sink-float-float-float-float-float-float-float, float-float-float-float-float-float-float-float, sink ... The double-layer structure consists of 6 heddles with the warp yarns at the floating point, and the weft yarns at the sinking point. The double-layer structure repeats: floating, sinking, ...

[0039] like Figure 1 and Figure 5 As shown, the surface of the first damping layer 5 has several first through holes 7, and the surface of the second damping layer 6 has several second through holes 8. Both the first through holes 7 and the second through holes 8 are formed by double-layer structure. The damping zone will form the first through holes 7 and the second through holes 8 during the weaving process. The first through holes 7 and the second through holes 8 are staggered. The weaving methods of the first through holes 7 and the second through holes 8 are different, so that the first through holes 7 and the second through holes 8 can be staggered. Both the first through holes 7 and the second through holes 8 are used to increase the amount of air passing through the outer layer 1. At the same time, during the process of air passing through the outer layer 1, the vibration of the air can be reduced.

[0040] like Figure 2 and Figure 3As shown, the noise reduction layer 2 located on both sides of the ventilation slot 4 has a guide slot 9. The cross-section of the guide slot 9 is triangular. The guide slot 9 is used to guide the air passing through the outer layer 1 into the noise reduction layer 2, thereby reducing the amount of air that is directly bounced back after being blown into the vibration damping zone. The guide slot 9 is connected to the ventilation slot 4. Several fibers 10 are fixedly connected to the noise reduction layer 2 located in the guide slot 9. Gaps are formed in the fibers 10, so that the fibers 10 themselves have a good vibration damping effect. Spacing is also formed between the fibers 10, so that the air in the spacing can generate complex flow and the vibration is absorbed by the fibers 10 in the spacing.

[0041] like Figure 1 and Figure 6 As shown, the outer layer 1 is woven from the warp and weft of the cushioning yarn 11. The cushioning yarn 11 is woven from the warp and weft of the outer layer 1 using a loom. The cushioning yarn 11 is made by twisting polyester profiled cross-section fibers 12 and carbon fibers 13. Both polyester profiled cross-section fibers 12 and carbon fibers 13 are twisted by a twisting machine to form the cushioning yarn 11. Both polyester profiled cross-section fibers 12 and carbon fibers 13 have good shock absorption properties. In addition, polyester profiled cross-section fibers 12 have good stiffness properties, which makes the cushioning yarn 11 less prone to wrinkling and has a shock absorption effect, thereby extending the service life of the cushioning yarn 11. The cross-sectional shape of polyester profiled cross-section fibers 12 is triangular. Triangular polyester profiled cross-section fibers 12 have good bulkiness properties, making the cushioning yarn 11 feel comfortable to the touch.

[0042] like Figure 2 and Figure 7 As shown, the noise reduction layer 2 is woven from noise reduction yarn 14 using a loom. The noise reduction yarn 14 includes a yarn core 15 and a covering layer 16 located outside the yarn core 15. The yarn core 15 is formed by twisting spandex fiber 17 and polyester fiber 18. The spandex fiber 17 has good elasticity, allowing the yarn core 15 to return to its original length after being stretched. The spandex fiber 17 and polyester fiber 18 are twisted to form the noise reduction yarn 14 using a twisting machine. The covering layer 16 is formed by twisting polyester fiber 18 and carbon fiber 13. The covering layer 16 has good wear resistance and shock absorption properties. The covering layer 16 is spirally wound around the outside of the yarn core 15 using a spinning machine. The noise reduction yarn 14 has good wear resistance, noise reduction, and elasticity.

[0043] like Figure 1 and Figure 8As shown, the inner layer 3 is woven from abrasion-resistant yarn 19. The abrasion-resistant yarn 19 is woven from a weft and warp on a loom to form the inner layer 3. The abrasion-resistant yarn 19 is formed by twisting several polyester fibers 18. The polyester fibers 18 are twisted by a twisting machine to form the abrasion-resistant yarn 19, which gives the abrasion-resistant yarn 19 good abrasion resistance.

[0044] The manufacturing process of polyester grey fabric includes,

[0045] Step 1: Weaving, using a shuttle loom to weave the outer layer 1, noise reduction layer 2, and inner layer 3 separately;

[0046] Step 2: Cutting. Using a cutting machine, ventilation grooves 4 are cut out on the noise reduction layer 2, and then guide grooves 9 are hot-pressed out.

[0047] Step 3: Preliminary stitching, using a sewing machine to sew the inner layer 3 and the noise reduction layer 2 together;

[0048] Step 4: Flocking, the flocking is performed in the guide groove 9 using a flocking machine;

[0049] Step 5: Final shaping. The inner layer 3, noise reduction layer 2, and outer layer 1 are sewn together using a sewing machine, and then post-processing is performed.

[0050] like Figure 2 and Figure 3 As shown, the noise reduction layer 2 is cut into a circular cross-section ventilation groove 4 by cutting. Then, the noise reduction layer 2 is transported to a hot press and a guide groove 9 is hot-pressed out. The noise reduction layer 2 located in the guide groove 9 will become thinner after hot pressing, so the inner layer 3 and the noise reduction layer 2 are sewn together by a sewing machine to thicken the noise reduction layer 2. Then, flocking is performed in the guide groove 9 by a flocking machine so that the noise reduction layer 2 located in the guide groove 9 has pile 10 fixed on it. Finally, the inner layer 3, the noise reduction layer 2 and the outer layer 1 are sewn together by a sewing machine.

[0051] Working principle:

[0052] When a person uses the soundproof room, the sound-generating device inside emits sound, which is transmitted to the outer layer 1. The pores in the outer layer 1 act as a damping layer. Some of the sound passes through the damping zone of the outer layer 1 and is transmitted to the noise reduction layer 2. Because sound causes airflow, the airflow exerts a force on the first damping layer 5 and the second damping layer 6, causing deformation of the first damping layer 5 and the second damping layer 6 within the damping zone. The second damping layer 5 and the second damping layer 6 deform as a result. The elasticity of the damping layer 6 is greater than that of the first damping layer 5, so the second through hole 8 on the second damping layer 6 will deform more than the first through hole 7. After deformation, the first through hole 7 and the second through hole 8 will become larger, thereby increasing the amount of air passing through the first through hole 7 and the second through hole 8. At the same time, the first damping layer 5 and the second damping layer 6 will be further apart. The air passing through the first through hole 7 and the second through hole 8 will flow into the pile 10 under the guidance of the guide groove 9. The pile 10 further enhances the noise reduction effect of the noise reduction layer 2.

[0053] When the soundproof room is not in use, the first damping layer 5 and the second damping layer 6 will return to their initial shape. Because the first through hole 7 and the second through hole 8 are misaligned, the damping zone can have a good dustproof effect. This means that when there is sound, the first damping layer 5 and the second damping layer 6 will deform, thereby increasing the amount of air passing through the first through hole 7 and the second through hole 8. Then, noise reduction is achieved through the fluff 10, the inner layer 3, and the noise reduction layer 2. When there is no sound, the first damping layer 5 and the second damping layer 6 will return to their original shape, giving the first damping layer 5 and the second damping layer 6 a better dustproof effect.

[0054] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A polyester grey fabric, characterized in that: The system includes an outer layer (1), to which a noise reduction layer (2) and an inner layer (3) are fixedly connected in sequence. Both the noise reduction layer (2) and the outer layer (1) have several ventilation slots (4) on their surfaces. The outer layer (1) located at the ventilation slots (4) is fixedly connected to a damping zone whose pore size increases with vibration. The damping zone includes a first damping layer (5) and a second damping layer (6). The first damping layer (5) is fixedly connected to the side away from the inner layer (3). The second damping layer (6) has greater elasticity than the first damping layer (5). The surface of the first damping layer (5) has several first through holes (7), and the surface of the second damping layer (6) has several second through holes (8). The first through holes (7) and the second through holes (8) are staggered. The noise reduction layer (2) located on both sides of the ventilation slots (4) has guide grooves (9) connected to the ventilation slots (4). The noise reduction layer (2) located in the guide groove (9) is fixedly connected with several fibers (10). The damping zone is set as a double-layer structure. The surface structure of the double-layer structure is 10 pages with the warp float as floating and the weft float as sinking. The structure cycle of the surface structure of the double-layer structure from left to right and from bottom to top is: sinking-float-sinking-float-sinking-float-sinking-float-sinking-float, floating-float-float-float-sinking-sinking-sinking-sinking-sinking-sinking-sinking, sinking-float-sink ... The double-layer structure has 6 heddles and its warp weft ...

2. The polyester grey fabric according to claim 1, characterized in that: The outer layer (1) is woven from the warp and weft of the buffer yarn (11), which is made by twisting polyester profiled cross-section fiber (12) and carbon fiber (13). The cross-sectional shape of the polyester profiled cross-section fiber (12) is triangular.

3. The polyester grey fabric according to claim 2, characterized in that: The noise reduction layer (2) is woven from noise reduction yarn (14) and includes a yarn core (15) and a covering layer (16) located outside the yarn core (15). The yarn core (15) is made by twisting spandex fiber (17) and polyester fiber (18), and the covering layer (16) is made by twisting polyester fiber (18) and carbon fiber (13). The covering layer (16) is spirally wound around the outside of the yarn core (15).

4. The polyester grey fabric according to claim 3, characterized in that: The inner layer (3) is woven from abrasion-resistant yarn (19) through warp and weft, and the abrasion-resistant yarn (19) is formed by twisting several polyester fibers (18).

5. A process for preparing polyester grey fabric, used in the production of the polyester grey fabric according to any one of claims 1-4, characterized in that: include, Step 1: Weaving, the outer layer (1), noise reduction layer (2) and inner layer (3) are woven together by a shuttle loom. Step 2: Cutting. Using a cutting machine, cut ventilation grooves (4) into the noise reduction layer (2), and then hot press out guide grooves (9); Step 3: Preliminary stitching, using a sewing machine to stitch the inner layer (3) and the noise reduction layer (2); Step 4: Flocking, the flocking is performed in the guide groove (9) by a flocking machine; Step 5: Final shaping. The inner layer (3), noise reduction layer (2) and outer layer (1) are sewn together using a sewing machine and then post-processed.

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