A method for weaving a high-strength high-elasticity warp-knitted fabric

Abstract

This invention discloses a method for weaving high-strength, high-elasticity warp-knitted fabric, including warping, weaving, degreasing, pre-setting, dyeing, opening, post-setting, and finished product inspection. It employs a four-bar integrated weaving method, wherein the padding yarn method and yarn configuration are as follows: bar GB1 and GB2 use spandex elastic yarn, woven in a mesh structure to form an elastic layer, exposed on both sides of the fabric, forming an anti-slip surface; bar GB3 uses high-elastic nylon yarn, woven in a weft-inserting structure, hidden in the middle of the fabric, while also increasing the fabric's tear strength. The warp-knitted fabric produced using the weaving method provided by this invention has high tensile strength, high modulus, and high recovery rate, giving the garment excellent body-shaping properties. The garment will not expand or loosen with increased wear and washing, and the fabric has good skin-friendly properties, with the fabric surface not easily slipping against the skin.

Description

Technical Field

[0001] This invention relates to the field of textile production technology, specifically to a method for weaving high-strength, high-elasticity warp-knitted fabrics. Background Technology

[0002] Currently, knitted fabrics have become an indispensable part of daily life, and increasingly more knitted garments offer both comfort and aesthetic appeal. Warp-knitted fabrics are widely used in women's underwear, shapewear, and other garments. Modern women are increasingly focused on fashion, and clothing with body-shaping functions is gaining popularity.

[0003] For example, application number 201610482463.5 discloses a method for preparing a stretch-gradient color warp-knitted material. By controlling the warp and weft density, the finished fabric is a single color under natural conditions, only showing color changes under stress. The color change on the fabric surface indicates the location and nature of the stress. When wearing clothing made from this fabric, the amount of movement and stress can be judged based on the color change on the fabric surface during exercise. Simultaneously, the color change further accentuates the beauty of the body's lines. The prepared warp-knitted material has a certain degree of resilience and modulus, and the sportswear made from it provides a certain degree of compression and a shaping effect.

[0004] However, traditional garments with body-shaping functions are heavy, and after prolonged wear and washing, the garments tend to expand and loosen, affecting the wearing experience and body-shaping function. This paper presents a new warp-knitted fabric and its weaving method, producing a lightweight fabric that, while satisfying body-shaping needs, also exhibits good resistance to deformation and sagging. Summary of the Invention

[0005] To overcome the problems existing in the prior art, the present invention provides a new warp-knitted fabric and its weaving method. The fabric and clothing prepared are lightweight and thin, and while satisfying the requirements of body shaping, they also have good anti-deformation and anti-sag properties.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for weaving a high-strength, high-elasticity warp-knitted fabric includes the following steps: warping, fabric weaving, degreasing, pre-setting, dyeing, opening, post-setting, and finished product inspection;

[0008] The warp-knitted fabric is woven using a four-comb knitting process.

[0009] In the weaving process, the method of padding and the yarn configuration are as follows:

[0010] GB1: 10 / 12 / 21 / 23 / 21 / 12 / / , using spandex elastic yarn, woven in a mesh structure, using a 1-through-1-open yarn threading method;

[0011] GB2: 23 / 21 / 12 / 10 / 12 / 21 / , using spandex elastic yarn, woven in a mesh structure, using a 1-through-1-open yarn threading method;

[0012] GB3:00 / 11 / 00 / 22 / 11 / 22 / / , uses high-elastic nylon yarn, woven with a weft-inserted structure and hidden in the middle of the fabric during weaving, and adopts a full-thread yarn-threading method;

[0013] GB4: 11 / 00 / / , uses spandex elastic yarn, woven with a weft-inserted structure, and adopts a full-thread yarn-threading method; the linear density of the spandex elastic yarn used in GB1, GB2, and GB4 is greater than the linear density of the high-elastic nylon yarn used in GB3.

[0014] GB1 and GB2 are woven together to form an elastic layer.

[0015] Preferably, GB1 and GB2 use spandex elastic yarn with the following specifications: 40D spandex elastic yarn and spandex content of 21.5%-28.5%;

[0016] The GB3 standard uses high-elastic nylon yarn with the following specifications: 20D / 24F semi-dull high-elastic nylon yarn and a nylon content of 15%-16%.

[0017] The specifications of the spandex elastic yarn used in GB4 are: 140D spandex elastic yarn with a spandex content of 26%-30%.

[0018] Preferably, the degreasing step employs a water washing process, with the water washing temperature varying in stages, including a hot washing stage, a warm washing stage, and a cold washing stage.

[0019] Preferably, the temperature range of the hot washing stage is 80-88℃, the temperature range of the warm washing stage is 70-75℃, and the temperature range of the cold washing stage is 52-55℃.

[0020] Preferably, the water washing temperatures are, in sequence: 80℃, 85℃, 75℃, 73℃, 55℃, and 54℃.

[0021] Preferably, the warping operation is as follows: a warping machine is used.

[0022] The 40D spandex elastic yarn uses a 70% draw ratio and a warping machine speed of 220m / min;

[0023] The 140D spandex elastic yarn uses a 60% draw ratio and a warping speed of 180m / min;

[0024] The warping speed for 20D / 24F semi-dull high-elastic nylon yarn is 400m / min, and the warping tension is 4.5-5.5g.

[0025] Preferably, during the warping step, the ambient temperature is maintained at 22-26°C and the relative humidity is maintained at 65%-70%.

[0026] Preferably, GB3 is woven using a 2-needle weft-insertion structure, and GB4 is woven using a 1-needle weft-insertion structure.

[0027] Preferably, in the predetermined step, the setting temperature is 200±2℃ and the setting speed is 23-25m / minute.

[0028] The finished product inspection shall include at least the following indicators: weight, width, elongation, modulus, and resilience.

[0029] In summary, the beneficial effects of the above-mentioned technical solution of the present invention are as follows:

[0030] In this invention, combs GB1 and GB2 are made of spandex elastic yarn, woven in a mesh structure to form an elastic layer. GB1, GB2, and GB4 all use spandex elastic yarn, and the linear density of spandex elastic yarn is much greater than that of high-elastic nylon yarn. Therefore, the spandex is exposed on both sides of the fabric, forming a non-slip surface, making the fabric have good skin-friendly properties and preventing slippage when in contact with the skin. Comb GB3 uses high-elastic nylon yarn, woven in a weft-inserted structure and hidden in the middle of the fabric, which also increases the tear strength of the fabric. This fabric has high tensile strength, high modulus, and high recovery rate, giving the garment excellent body-shaping function. The garment will not expand or loosen with increased wear and washing. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 A schematic diagram of the completed fabric in the weaving method of a high-strength, high-elasticity warp-knitted fabric provided by the present invention;

[0033] Figure 2 The yarn padding motion diagram of GB1 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0034] Figure 3 The yarn padding motion diagram of GB2 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0035] Figure 4 The yarn padding motion diagram of GB3 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0036] Figure 5 The yarn padding motion diagram of GB4 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0037] Figure 6 The continuous yarn padding motion diagram of GB1 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0038] Figure 7 The continuous yarn padding motion diagram of GB2 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0039] Figure 8 The continuous yarn movement diagram of GB3 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention;

[0040] Figure 9 The continuous yarn movement diagram of GB4 in the weaving method of a high-strength and high-elasticity warp-knitted fabric provided by the present invention. Detailed Implementation

[0041] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0042] Example 1

[0043] like Figures 1-9 As shown, the present invention provides a method for weaving high-strength and high-elasticity warp-knitted fabric, including the following steps: warping, weaving, degreasing, pre-setting, dyeing, opening, post-setting, and finished product inspection;

[0044] ① Warping: The purpose of warping is to evenly wind the yarn required for weaving onto the warp beam of the warping machine with a certain tension according to the number and length required by the weaving process, so that it can be used by the warp knitting machine. The guide bars GB1, GB2 and GB4 can be made of spandex of the same or different thicknesses, while the guide bar GB3 is made of high-elastic nylon yarn.

[0045] In this embodiment, the yarn configuration includes four types: GB1, GB2, GB3, and GB4. The four types of yarn need to be wound onto the warp beam in a certain order and according to process parameters.

[0046] Specifically,

[0047] GB1 and GB2 use spandex elastic yarn, with specifications of 40D spandex elastic yarn and a spandex content of 21.5%-28.5%;

[0048] GB3 uses high-elastic nylon yarn, with specifications of 20D / 24F semi-dull high-elastic nylon yarn and a nylon content of 15%-16%;

[0049] GB4 uses spandex elastic yarn, with specifications of 140D spandex elastic yarn and a spandex content of 26%-30%.

[0050] During the warping process, 40D spandex elastic yarn is drawn at a 70% draw ratio, and the warping machine speed is 215-220 m / min, preferably 220 m / min; 140D spandex elastic yarn is drawn at a 60% draw ratio, and the warping machine speed is 170-185 m / min, preferably 180 m / min; 20D / 24F semi-dull high-elastic nylon yarn is warped at a speed of 380-410 m / min, preferably 400 m / min, with a warping tension of 4.5-5.5 g; the ambient temperature is maintained at 22-26℃, and the relative humidity is maintained at 65%-70%.

[0051] ② Weaving: The weaving is performed on a 28-gauge warp knitting machine, using a four-comb knitting method. The yarn padding method and yarn configuration are as follows:

[0052] GB1: 10 / 12 / 21 / 23 / 21 / 12 / / , such as Figure 2 and Figure 6 As shown, it uses spandex elastic yarn, woven in a mesh structure, and employs a 1-through-1-open yarn threading method;

[0053] GB2: 23 / 21 / 12 / 10 / 12 / 21 / , such as Figure 3 and Figure 7 As shown, it uses spandex elastic yarn, woven in a mesh structure, and employs a 1-through-1-open yarn threading method;

[0054] GB3: 00 / 11 / 00 / 22 / 11 / 22 / / , such as Figure 4 and Figure 8 As shown, high-elastic nylon yarn is used, and it is woven with a weft-inserted structure and hidden in the middle of the fabric during weaving; GB3 can be woven with a 2-needle weft-inserted structure or a multi-needle weft-inserted structure, and a full-thread yarn-threading method is used.

[0055] GB4: 11 / 00 / / , such as Figure 5 and Figure 9 As shown, it uses spandex elastic yarn and is woven with a weft-insertion structure; it is woven with a 1-needle weft-insertion structure or a multi-needle weft-insertion structure and uses a full-thread yarn-threading method;

[0056] The linear density of the spandex elastic yarn used in GB1, GB2, and GB4 is greater than the linear density of the high-elastic nylon yarn used in GB3.

[0057] GB1 and GB2, after weaving, form an elastic layer, which increases the overall elastic modulus and stretchability of the warp-knitted fabric, resulting in good elongation and recovery rate. The guide bar GB3 uses high-elastic nylon yarn in a weft-inserted structure, woven and hidden in the middle of the fabric, while also increasing the fabric's tear strength. Because GB3 uses high-elastic nylon yarn, it is hidden in the middle of the fabric during weaving; GB1, GB2, and GB4 all use spandex elastic yarn, and the linear density of spandex elastic yarn is much greater than that of high-elastic nylon yarn. Therefore, the spandex is exposed on both sides of the fabric, forming a non-slip surface, making the fabric have good skin-friendly properties and less prone to slipping when in contact with the skin.

[0058] The finished fabric is called grey cloth.

[0059] ③ Degreasing: The degreasing step employs a water washing process. During the weaving process, due to tension, the fabric undergoes significant tensile deformation, resulting in substantial residual stress in the greige fabric. This stress causes fabric structure deformation, making it difficult to control quality indicators such as the number of webs and weight per square meter, significantly impacting subsequent dyeing and finishing processes. The greige fabric passes through a washing machine and undergoes relaxation treatment under steam or hot water at a specific temperature. This removes oil, dirt, and soil from the greige fabric, while simultaneously relaxing its tension and internal stress. The greige fabric passes through the washing machine at a speed of 20-22 m / min, with a washing tension of 15g. The washing temperature inside the machine varies in stages, including soaking and boiling, hot washing, warm washing, and cold washing. The hot washing stage temperature ranges from 80-88℃, the warm washing stage from 70-75℃, and the cold washing stage from 52-55℃. Preferably, the washing temperature changes in a stepped manner, namely: 80℃, 85℃, 75℃, 73℃, 55℃, and 54℃. Among them, 80℃ and 85℃ are the hot washing stages, 75℃ and 73℃ are the warm washing stages, and 55℃ and 54℃ are the cold washing stages. The first stage uses higher temperatures for soaking and boiling to relax the fabric and effectively remove oil and dirt from it. At the same time, the original fabric is under tension during the weaving process due to various tensions, and the spacing between the warp and weft is obvious and relatively loose. By using a three-stage washing method, the fabric is subjected to high temperature, high pressure, and external force during the washing process. Under the heat, the shape and size of the fibers change and shrink, causing the warp and weft of the fabric to shrink to a certain extent, so that the fabric reaches a new mechanically stable state. Compared to traditional washing methods, the washing temperature decreases slowly, involving hot washing, warm washing, and cold washing in sequence. This process prevents excessive temperature differences from causing unstable shrinkage rates in the fabric and affecting its quality. It also eliminates potential shrinkage within the fabric, allowing it to shrink back beforehand, thus reducing the shrinkage rate of the finished product. After washing, a small amount of high-elastic nylon yarn slips and becomes exposed on the front side, making the fabric more compact without affecting its overall elastic modulus and stretchability, further enhancing its tear strength.

[0060] ④ Pre-setting: The pre-setting process involves evenly and loosely distributing the greige fabric to be set in the fabric cart. Process conditions: machine width 146cm, temperature 198℃, air force 80%-85%, greige fabric speed 23-25m / min. After sufficient relaxation by washing, heat setting is performed to stabilize the greige fabric size, reduce shrinkage, and prevent defects such as wrinkles, rope wrinkles, and thin lines from occurring during subsequent wet processing such as dyeing.

[0061] ⑤ Dyeing: Acid dyes, mordant dyes, metal complex dyes, disperse dyes and vat dyes are usually used to dye the greige fabric.

[0062] ⑥ Width Unfolding: The dyed colored fabric is unfolded to achieve the standard width, correcting defects such as uneven width, weft skew, and uneven sheen that occurred during the dyeing and printing process. This ensures the fibers within the fabric are in a more suitable natural alignment, reducing factors that cause fabric deformation. This avoids the main causes of shrinkage, wrinkles, and a rough hand feel. Mechanical clamps can be used to gradually widen the fabric towards the selvage, followed by slow drying to achieve temporary shaping.

[0063] ⑦ Final shaping: The final shaping is carried out, and mechanical finishing can be used to give the surface a certain pattern and electro-optical effect.

[0064] ⑧ Finished product inspection: Inspection indicators should include at least: weight, width, longitudinal density, transverse density, tensile strength, modulus, and resilience.

[0065] Example 2

[0066] Yarn configuration:

[0067] GB1: 40D spandex elastic yarn; spandex content 21.5%;

[0068] GB2: 40D spandex elastic yarn; spandex content 21.5%;

[0069] GB3: 20D / 24F semi-dull high-elastic nylon yarn;

[0070] GB4: 140D spandex elastic yarn; spandex content is 29%.

[0071] The quantity of weaving raw materials includes:

[0072] GB1: 40D spandex elastic yarn, 295 pieces;

[0073] GB2: 40D spandex elastic yarn, 295 pieces;

[0074] GB3: 20D / 24F semi-dull high-elastic nylon yarn, 588 pieces;

[0075] GB4: 140D spandex elastic yarn, 588 pieces.

[0076] Warping: 670 warping heads for 40D spandex elastic yarn, with a 70% draw ratio and a warping machine speed of 220m / min; 668 warping heads for 140D spandex elastic yarn, with a 60% draw ratio and a warping machine speed of 180m / min; 668 warping heads for 20D / 24F semi-dull high-elastic nylon yarn, with a warping machine speed of 400m / min and a warping tension of 4.5-5.5g; the warping environment temperature is maintained at 22-26℃ and the relative humidity is maintained at 65%-70%.

[0077] Weaving: The knitting is performed on a 28-gauge warp knitting machine, model RES4-1-28; it is woven using a four-comb knitting method, with the following yarn backing and yarn configuration:

[0078] GB1: 10 / 12 / 21 / 23 / 21 / 12 / / , woven with a mesh structure, using a 1-through-1-open yarn threading method;

[0079] GB2: 23 / 21 / 12 / 10 / 12 / 21 / , woven with a mesh structure, using a 1-through-1-open yarn threading method;

[0080] GB3:00 / 11 / 00 / 22 / 11 / 22 / / , woven with a weft-insertion structure and hidden in the middle of the fabric during weaving; woven with a 2-needle or multi-needle weft-insertion structure, using a full-through yarn threading method;

[0081] GB4:11 / 00 / / , knitted with a weft-insertion structure; knitted using a 1-needle or multi-needle weft-insertion structure, using a full-thread yarn-threading method;

[0082] The weaving process is completed to obtain the raw fabric.

[0083] Degreasing: The speed at which the fabric passes through the washing machine is 22m / min, the washing tension is 15g, and the washing temperature inside the washing machine is changed in stages in different zones, including soaking and boiling, hot washing, warm washing and cold washing, with the changing temperatures being 80℃, 85℃, 75℃, 73℃, 55℃ and 54℃ respectively.

[0084] Pre-planning: Distribute the fabric to be shaped evenly and loosely in the fabric car. Process conditions: machine width 146cm, temperature 198℃, wind force 80%-85%, fabric speed 25m / min, tension 4kg after passing through the rolling mill.

[0085] The process includes dyeing, drying, and post-setting. The post-setting process uses a setting machine with a setting temperature of 150℃, a setting speed of 28m / minute, and an air force of 70%.

[0086] The finished product specification is 95g / m³. 2 *135cm, where 135cm indicates the width and approximately 95g / m². 2 .

[0087] Finished product inspection: Inspection indicators must include at least: weight, width, longitudinal density, transverse density, tensile strength, modulus, and resilience. The results of the finished product inspection are shown in the table below:

[0088] Table 1 Finished Product Inspection Results

[0089]

[0090] The longitudinal density refers to the number of rows of coils within 1 cm along the longitudinal direction of the warp-knitted fabric, while the transverse density refers to the number of rows of coils within 1 cm along the longitudinal direction of the warp-knitted fabric.

[0091] 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 method for weaving a high-strength, high-elasticity warp-knitted fabric, characterized in that: Includes the following steps: Warping, fabric weaving, degreasing, pre-setting, dyeing, opening, finishing and finished product inspection; The warp-knitted fabric is woven using a four-comb knitting process. In the fabric weaving process, the padding method and yarn configuration are as follows: GB1: 10 / 12 / 21 / 23 / 21 / 12 / / , using spandex elastic yarn, woven in a mesh structure, using a 1-through-1-open yarn threading method; GB2: 23 / 21 / 12 / 10 / 12 / 21 / , using spandex elastic yarn, woven in a mesh structure, using a 1-through-1-open yarn threading method; GB3:00 / 11 / 00 / 22 / 11 / 22 / / , uses high-elastic nylon yarn, woven with a weft-inserted structure and hidden in the middle of the fabric during weaving, and adopts a full-thread yarn-threading method; GB4:11 / 00 / / , using spandex elastic yarn, woven with a weft-inserted structure, and using a full-thread yarn threading method; The linear density of the spandex elastic yarn used in GB1, GB2, and GB4 is greater than the linear density of the high-elastic nylon yarn used in GB3. GB1 and GB2 are woven together to form an elastic layer; GB1 and GB2 use spandex elastic yarn with the following specifications: 40D spandex elastic yarn and spandex content of 21.5%-28.5%; The GB3 standard uses high-elastic nylon yarn with the following specifications: 20D / 24F semi-dull high-elastic nylon yarn and a nylon content of 15%-16%. The specifications of the spandex elastic yarn used in GB4 are: 140D spandex elastic yarn with a spandex content of 26%-30%; The warping operation is as follows: a warping machine is used. 40D spandex elastic yarn uses a 70% draw ratio and a warping machine speed of 215-220m / min; The 140D spandex elastic yarn uses a 60% draw ratio and a warping speed of 170-185m / min; The warping speed for 20D / 24F semi-dull high-elastic nylon yarn is 380-410m / min, and the warping tension is 4.5-5.5g. The degreasing step adopts a water washing process, and the water washing temperature is changed in stages, including a hot washing stage, a warm washing stage and a cold washing stage. The temperature range for the hot washing stage is 80-88℃, the temperature range for the warm washing stage is 70-75℃, and the temperature range for the cold washing stage is 52-55℃.

2. The method of claim 1, wherein the method further comprises: The water washing temperatures are as follows: 80℃, 85℃, 75℃, 73℃, 55℃, and 54℃.

3. The method of claim 1, wherein the method further comprises: During the warping process, the ambient temperature is maintained at 22-26℃ and the relative humidity is maintained at 65%-70%.

4. The weaving method for a high-strength, high-elasticity warp-knitted fabric according to claim 1, characterized in that: GB3 is woven using a 2-needle weft insertion structure, while GB4 is woven using a 1-needle weft insertion structure.

5. The weaving method for a high-strength, high-elasticity warp-knitted fabric according to claim 1, characterized in that: In the predetermined steps, the setting temperature is 200±2℃ and the setting speed is 23-25m / minute.

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