Sunshade cloth and manufacturing method

Abstract

The application relates to a sunshade cloth and a manufacturing method, and relates to the technical field of cloth fabrics. The sunshade cloth comprises warp and weft, the warp comprises warp core threads and a first sunshade layer, the weft comprises weft core threads and a second sunshade layer, and the first sunshade layer and the second sunshade layer are both made of PVC raw materials, titanium white and carbon black. The warp and the weft are obtained by mixing the PVC raw materials, the titanium white and the carbon black, then the warp and the weft are flatly woven to obtain the sunshade cloth. The titanium white can reflect light, and the carbon black can absorb light, so that the sunshade effect of the sunshade cloth is improved.

Description

Technical Field

[0001] This application relates to the technical field of fabrics, and in particular to a light-blocking fabric and a method for manufacturing it. Background Technology

[0002] As people's living standards improve and their pace of life accelerates, their requirements for fabrics are also getting higher and higher, especially the ability to block out light.

[0003] Most blackout roller blinds on the market today use a coating process, which is prone to hardening, sticking, and delamination, resulting in poor overall integrity. Their blackout function mainly relies on the blackout layer adhered to the fabric layer. Once the blackout layer is damaged, the blackout effect will be greatly reduced, thereby reducing the blackout effect of the fabric. Summary of the Invention

[0004] To improve the light-blocking effect of fabric, this application provides a light-blocking fabric and a manufacturing method thereof.

[0005] Firstly, this application provides a light-blocking fabric, which adopts the following technical solution:

[0006] A light-blocking fabric includes warp yarns and weft yarns woven in a plain weave with the warp yarns. The warp yarns include warp core yarns and a first light-blocking layer covering the warp core yarns. The weft yarns include weft core yarns and a second light-blocking layer covering the weft core yarns. The materials used to prepare the first light-blocking layer and the second light-blocking layer both include PVC, titanium dioxide, and carbon black.

[0007] By adopting the above technical solution, using PVC as a carrier, titanium dioxide and carbon black are added and mixed, and then wrapped on the warp core to form a first light-blocking layer, and wrapped on the weft core to form a second light-blocking layer, thus obtaining warp and weft threads. The warp and weft threads are then plain woven to obtain a light-blocking fabric. Therefore, titanium dioxide reflects light, reducing the light that moves to the warp and weft weaving nodes, while carbon black can absorb the light that moves to the warp and weft threads, especially to the warp and weft weaving nodes, reducing the probability of light passing through the weaving nodes, thereby improving the light-blocking effect of the light-blocking fabric.

[0008] Optionally, the weaving density of the fabric is set according to the following formula: A1*W1≥25.4mm, and A2*W2+(A2-1)*W1≥25.4mm;

[0009] Where A1 is the weaving density of the warp, A2 is the weaving density of the weft, W1 is the minimum width of the warp, and W2 is the minimum width of the weft. During weaving, the warp passes between two adjacent wefts and the two adjacent warp abuts or presses against each other.

[0010] By adopting the above technical solution, the weft yarn passes between two adjacent warp yarns, and there are A1 warp yarns within one inch. Since A1*W1≥25.4mm, the first light-blocking layers on the two adjacent warp yarns abut or press against each other. The number of weft yarns is A2, and since the warp yarns pass between two adjacent weft yarns, the number of warp yarns located between the two adjacent weft yarns is A2-1. Since A2*W2+(A2-1)*W1≥25.4mm, the first and second light-blocking layers abut or press against each other, thereby sealing the warp and weft yarn weaving nodes. This reduces the size of the gaps at the warp and weft yarn weaving nodes, further reducing the probability of light passing through the warp and weft yarn weaving nodes, making the light passing through the light-blocking cloth extremely low, or even achieving an opaque effect, further improving the light-blocking effect of the light-blocking cloth.

[0011] Optionally, both the warp and weft cores are black cores, and the first light-shielding layer comprises the following raw materials by weight fraction:

[0012]

[0013] By adopting the above technical solution, the first and second light-blocking layers are light-colored, thus providing light-colored core wires and offering more color options. The increased amount of titanium dioxide reflects light, while a small amount of carbon black absorbs light without changing color. Combined with the weaving density of the two layers, the amount of light passing through the fabric is greatly reduced, achieving an opaque effect and resulting in a fabric with better light-blocking performance.

[0014] Optionally, both the warp and weft cores are white cores, and the first light-shielding layer comprises the following raw materials by weight fraction:

[0015]

[0016] By adopting the above technical solution, the first and second light-blocking layers in this application are dark-colored, and the fabric produced can achieve the effects of reflection and light absorption, which greatly reduces the light passing through the fabric and achieves the effect of no light transmission; by adding a specific proportion of titanium dioxide and carbon black, the combination of titanium dioxide and carbon black makes the light reflected away from the weaving point, and the light reaching the weaving point is greatly reduced by the absorption effect of carbon black, thereby obtaining a fabric with better light-blocking effect.

[0017] The black core and white PVC can make the first and second light-blocking layers opaque, or, when combined with the weaving density, can further enhance the opacity, thus greatly improving the light-blocking effect of the blackout fabric.

[0018] Secondly, the manufacturing method provided in this application adopts the following technical solution:

[0019] A manufacturing method includes the following steps:

[0020] Preparation of the first and second light-shielding layers: Weigh various raw materials according to the proportion, and then mix the various raw materials to obtain the first and second light-shielding layers;

[0021] Preparation of warp and weft: The first and second light-blocking layers are extruded by a screw and then wrapped onto the warp core and weft core respectively to obtain the warp and weft;

[0022] Weaving: The warp and weft threads are woven using weaving equipment. During the weaving process, the weaving density of the warp and weft threads is controlled to meet the weaving requirements. At the same time, the temperature of the warp and weft threads is controlled during the weaving process. Heat setting: The warp and weft threads are heat set.

[0023] Testing: The light transmittance of the blackout fabric is tested.

[0024] By adopting the above technical solution, various raw materials are first granulated in proportion, and then extruded onto the warp and weft cores using a screw extruder to obtain raw warp and weft yarns. These yarns are then woven using a weaving machine. During the weaving process, the tension on the warp and weft yarns is controlled, causing them to stretch. After weaving, the tension disappears, causing the yarns to spring back, resulting in the flat areas of the first and second light-blocking layers pressing against each other. This seals the weaving nodes of the warp and weft yarns, reducing the probability of light transmission. Finally, the light transmittance of the light-blocking fabric is tested using a detection device. If the light transmittance meets the requirements, the tension during the weaving of the warp and weft yarns is adjusted to ensure the light transmittance of the subsequent light-blocking fabric meets the requirements, thereby further improving the light-blocking effect of the fabric.

[0025] Temperature is crucial to the performance of PVC raw materials. Excessive or insufficient temperature can cause changes in the PVC raw materials, affecting the light-blocking effect of the subsequent blackout fabric. At the same time, dust on the warp and weft threads can easily accumulate at the weaving joints, creating gaps and thus reducing the light-blocking effect. Therefore, by controlling the temperature of the warp and weft threads during the weaving process and cleaning the dust, the PVC material on the warp and weft threads is kept at a suitable temperature, reducing the amount of dust on the warp and weft threads and thereby improving the light-blocking effect of the blackout fabric.

[0026] Heat setting flattens the warp and weft threads, causing the flattened parts of the warp and weft threads to press together, thereby further reducing the gap between the warp and weft threads and improving the light-blocking effect of the blackout fabric.

[0027] Optionally, the weaving equipment is a rapier loom, which is equipped with a cooling pipe for cooling and controlling the temperature of the weft yarn. The rapier loom is also equipped with a cooling component and a temperature control absorption mechanism connected to the cooling pipe. The cooling component is used to cool and control the temperature of the weft yarn, and the temperature control absorption mechanism absorbs dust on the warp and weft yarns and controls the temperature of the warp yarn.

[0028] By adopting the above technical solution, the rapier loom guides only one weft yarn during production. Therefore, the weft yarn can be cooled and its temperature controlled by the cooling pipe and cooling components, thereby controlling the temperature of the second shading layer. Meanwhile, multiple warp yarns move together at a time. Therefore, the temperature of multiple warp yarns can be controlled by the temperature control absorption mechanism. At the same time, it can also absorb dust on the warp yarns and yarns, reducing the probability of dust adhering to the warp yarns and yarns and causing gaps at the warp and yarn weaving nodes, thereby further improving the shading effect of the shading cloth.

[0029] Optionally, the temperature control absorption mechanism includes:

[0030] An air outlet plate is provided on the rapier loom and located below the warp threads, and has air blowing holes for blowing upwards.

[0031] An air intake plate is provided on the rapier loom and located above the warp threads, and has air intake holes that allow gas and dust to enter.

[0032] A cooling box is installed on a rapier loom and is equipped with an air outlet pipe and an air inlet pipe that are respectively connected to an air blowing hole and an air inlet.

[0033] A fan is mounted on the cooling box and allows gas to be blown out through an air outlet and drawn in through an air intake.

[0034] The filter assembly and temperature control assembly are spaced apart on the cooling box, so that the gas is filtered by the filter assembly and then passes through the temperature control assembly to achieve temperature control.

[0035] By adopting the above technical solution, dust on the warp and weft threads rises, and at the same time, the fan starts. The dust rises and enters the filter assembly through the air intake hole and air intake pipe for collection. The filtered air is then heated to the required temperature by the temperature control component. The air is then blown to multiple warp threads through the air outlet pipe and air outlet, thereby raising the temperature of the warp threads to the required temperature and cleaning the dust on the yarn and weft threads, thus improving the shading effect of the blackout cloth.

[0036] Optionally, the filtering component includes:

[0037] A filter frame, which is horizontally slidably mounted on the cooling box and used to filter the gas and collect impurities; and a mounting plate, which is disposed on the filter frame and abuts against the cooling box for positioning.

[0038] By adopting the above technical solution, dust is moved into the filter frame for collection. When the filter frame needs to be cleaned, the mounting plate is pulled to remove the filter frame for cleaning. After cleaning, the filter frame is slid and installed on the cooling box, and the mounting plate is pushed against the cooling box for positioning, thereby achieving dust collection, improving the cleaning effect on warp and yarn, and improving the light-blocking effect of the blackout cloth.

[0039] Optionally, the temperature control component includes:

[0040] A cooling plate is provided inside a cooling box and has multiple ventilation holes that pass through it evenly. A cooling cavity is provided inside the cooling plate.

[0041] A control tube is mounted on a control board and communicates with a cooling chamber, both of which are filled with coolant.

[0042] A control piston, which is slidably mounted on a control tube and moves to adjust the amount of coolant in the cooling chamber;

[0043] A drive unit, which is mounted on a control tube and is used to drive and control the movement of a piston;

[0044] A temperature detector is installed on the rapier loom and is used to detect the temperature of the warp threads and is connected to the drive unit.

[0045] By adopting the above technical solution, air passes through multiple ventilation holes, while the coolant in the cooling chamber cools the air. The cooled air is then blown onto the warp threads through the exhaust pipe and exhaust holes for further cooling. Simultaneously, a temperature detector monitors the temperature of the warp threads. Based on the temperature, the temperature detector controls the drive unit, which activates and moves the control piston. The piston movement adjusts the amount of coolant in the cooling chamber. When the warp thread temperature is too high, the drive unit activates and moves the piston to push the coolant in the control pipe into the cooling chamber, thereby increasing the amount of coolant in the cooling chamber and improving the cooling effect on the air, thus lowering the temperature of the warp threads. When the warp thread temperature is too low, the operation is reversed to keep the warp thread temperature within a suitable range, improving the shading effect of the shading cloth.

[0046] Optionally, the control tube includes a horizontal section and a vertical section, the horizontal section being connected to the cooling chamber and the vertical section extending vertically downwards to below the horizontal section, with the control piston located below the horizontal section.

[0047] By adopting the above technical solution, the drive unit starts and drives the piston rod to move upward, which pushes the coolant in the control tube into the cooling chamber, thereby increasing the amount of coolant in the cooling chamber. When the drive unit moves in the opposite direction, the coolant in the cooling chamber flows into the control tube, thereby reducing the amount of coolant in the cooling chamber. This makes it easier to control the air temperature, keeping the warp yarn in a suitable temperature range and improving the shading effect of the shading cloth.

[0048] Optionally, the cooling pipe is provided with an inlet pipe for introducing gas, and the cooling assembly includes:

[0049] A receiving box is provided on a rapier loom and is filled with coolant. The air inlet pipe passes horizontally through the receiving box and the coolant, so that the coolant cools the gas in the air inlet pipe.

[0050] A control board, which is slidably mounted in the housing along the axis of the air inlet pipe and is used to control the length of the air inlet pipe in contact with the coolant;

[0051] A control component, which is disposed on the housing and connected to the control board and is used to drive the control board to move;

[0052] A temperature detector is installed on the cooling pipe and is used to detect the temperature of the gas entering the cooling pipe and is electrically connected to the control unit.

[0053] By adopting the above technical solution, gas enters the cooling pipe through the air inlet pipe, while the coolant cools the gas passing through the air inlet pipe. The cooled gas then cools the weft yarn, thereby guiding the weft yarn to cool itself. At the same time, a temperature detector is used to detect the temperature of the air entering the cooling pipe. Based on the temperature change, the control unit is activated to move the control plate. The movement of the control plate is used to adjust the contact length between the coolant and the air inlet pipe, thereby adjusting the length of the air inlet pipe in contact with the coolant. This achieves the adjustment of the temperature of the weft yarn, improving the shading effect of the shading cloth.

[0054] In summary, this application includes at least one of the following beneficial technical effects:

[0055] By mixing PVC raw materials, titanium dioxide, and carbon black, and then coating them onto the warp core to form the first light-blocking layer, and coating them onto the weft core to form the second light-blocking layer, warp and weft yarns are obtained. The warp and weft yarns are then plain-woven to form a light-blocking fabric. Therefore, titanium dioxide reflects light, while carbon black absorbs light, reducing the probability of light passing through the weaving nodes, thereby improving the light-blocking effect of the light-blocking fabric. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the structure of a blackout fabric;

[0057] Figure 2 This is a schematic diagram of the structure of the rapier loom, temperature control absorption mechanism, and cooling components in the manufacturing process;

[0058] Figure 3 This is a structural schematic diagram of the cooling assembly, showing a cross-section of the side wall of the housing.

[0059] Figure 4 This is a structural schematic diagram of the temperature control absorption mechanism, showing a cross-section of the cooling box, cooling plate, and vertical section.

[0060] Reference numerals: 1. Warp; 11. Warp core; 12. First light-shielding layer; 2. Weft; 21. Weft core; 22. Second light-shielding layer; 3. Rapier loom; 31. Cooling pipe; 32. Air inlet pipe; 4. Temperature control absorption mechanism; 41. Air outlet plate; 42. Air intake plate; 43. Cooling box; 431. Air intake pipe; 432. Air outlet pipe; 44. Fan; 45. Filter assembly; 46. Filter frame; 47. Mounting plate; 5. Temperature control assembly; 51. Cooling plate; 52. Control pipe; 521. Horizontal section; 522. Vertical section; 53. Control piston; 54. Drive component; 55. Temperature detector; 56. Ventilation hole; 57. Cooling chamber; 6. Cooling assembly; 61. Container box; 62. Control board; 63. Control component; 64. Temperature detector; 65. First space; 66. Second space. Detailed Implementation

[0061] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0062] This application discloses a light-blocking fabric.

[0063] Reference Figure 1 The light-blocking fabric includes warp 1 and weft 2 that forms a plain weave with the warp 1.

[0064] The warp 1 includes a warp core 11 and a first light-shielding layer 12 covering the warp core 11, while the weft 2 includes a weft core 21 and a second light-shielding layer 22 covering the weft core 21. The first light-shielding layer 12 and the second light-shielding layer 22 have the same composition and formula. The materials used to prepare the first light-shielding layer 12 include PVC, titanium dioxide, and carbon black. The titanium dioxide causes the light moving to the warp 1 and weft 2 to be reflected and dispersed, so that the light moves away from the warp 1 and weft 2. At the same time, the carbon black can also absorb the light moving to the warp 1 and weft 2, especially at the weaving nodes of the warp 1 and weft 2, thereby greatly reducing the light passing through the weaving nodes and improving the light-shielding effect of the light-shielding cloth.

[0065] Carbon black makes the first light-shielding layer 12 and the second light-shielding layer 22 elastic, controlling the weaving density of the warp 1 and weft 2. The weaving density of the fabric is set by the following formula: A1*W1≥25.4mm, and A2*W2+(A2-1)*W1≥25.4mm; where A1 is the weaving density of the warp 1, A2 is the weaving density of the weft 2, and the units of A1 and A2 are: threads / inch, that is, the number of threads within one inch; W1 is the minimum width of the warp 1, and W2 is the minimum width of the weft 2.

[0066] During weaving, the warp 1 passes between two adjacent weft 2, and the two adjacent warp 1 abut or press against each other. This causes the first light-blocking layer 12 and the second light-blocking layer 22 on the warp 1 and weft 2 to abut or press against each other after weaving. The first light-blocking layer 12 on the two adjacent warp 1 also abuts or presses against each other, thereby blocking the weaving node of the warp 1 and weft 2, reducing the probability of light passing through the weaving node, and improving the light-blocking effect of the light-blocking cloth.

[0067] Example 1

[0068] Reference Figure 1 Both warp core 11 and weft core 21 are black core wires. The PVC raw materials include light-colored PVC, plasticizer, antioxidant, heat stabilizer, flame retardant, and pigment. The light-colored PVC can be white, etc. The first light-shielding layer 12 includes the following raw materials by weight fraction:

[0069]

[0070] In this embodiment, the light-colored PVC is 52 parts, the plasticizer is 23 parts, the heat stabilizer is 1 part, the flame retardant is 6 parts, the titanium dioxide is 16 parts, the pigment is 0.3 parts, the carbon black is 0.2 parts, and the additives are 1.5 parts.

[0071] Raw material description:

[0072] PVC, Formosa Plastics Industrial (Ningbo) Co., Ltd., extrusion grade PVC;

[0073] Plasticizers, PVC plasticizers, Xingtianwai Chemical (Shanghai) Co., Ltd.;

[0074] Stabilizer, calcium-zinc stabilizer, BASF Chemical Co., Ltd.;

[0075] The titanium dioxide is rutile titanium dioxide with a TiO2 content of ≥96%, manufactured by Chemours Titanium Dioxide Technology.

[0076] Flame retardant, antimony trioxide, CAS number 1309-64-4, purity ≥99.5%;

[0077] Wollastonite powder, produced by Xinyu Nanfang Wollastonite Co., Ltd., is a white needle-like powder.

[0078] Examples 2-4

[0079] The difference between Examples 2-4 and Example 1 lies in the amount of each component raw material used.

[0080] The specific details are shown in Table 1 below.

[0081] Table 1. Raw materials and dosage of the first light-shielding layer 12 (unit: kg)

[0082]

[0083] Comparative Examples 1-4

[0084] Comparative Example 1

[0085] The difference between this comparative example and Example 4 is that no carbon black was added.

[0086] Comparative Example 2

[0087] The difference between this comparative example and Example 4 is that wollastonite powder of equal mass is used instead of titanium dioxide.

[0088] Comparative Examples 3-5

[0089] The difference between Comparative Examples 3-5 and Example 1 is that the amounts of each component raw material are different.

[0090] The specific details are shown in Table 2 below.

[0091] Table 2. Raw materials and dosage of the first light-shielding layer 12 (unit: kg)

[0092] PVC plasticizer stabilizer Titanium dioxide pigment Flame retardant carbon black additive Comparative Example 3 52 24 1 15. 0.3 6 0.2 1.5 Comparative Example 4 50 24 1 17. 0.4 6 0.1 1.5 Comparative Example 5 50 24 1 18. 0.4 5.5 0.1 1.

[0093] Performance Test 1

[0094] The light-blocking degree of the light-blocking cloths prepared in Examples 1-4 and Comparative Examples 1-5 was tested. During the test, the back of the light-blocking cloth was illuminated in a dark room using the same mobile phone backlight with a light intensity of 30-50 lumens, and then the light leakage of the front of the light-blocking cloth was observed by human eyes.

[0095] The experimental results are shown in Table 3 below.

[0096] Table 3 Results of the light-blocking test

[0097]

[0098]

[0099] As shown in Table 2, the curtain fabric produced in this application achieves complete light blocking, effectively eliminating all light. In Examples 1-4, the amount of titanium dioxide remained constant, and the effects of variations in the amounts of other components on the light-blocking degree of the blackout fabric were investigated. Example 4 is the preferred embodiment. In Comparative Examples 3-5, the light-blocking effect increased with increasing titanium dioxide content, but the effect stabilized after the amount of titanium dioxide exceeded 16 parts. Therefore, considering both the light-blocking effect and production cost, Example 4 is the preferred embodiment.

[0100] By covering the core wires with light-colored PVC, the fabric becomes light-colored. Then, a large amount of titanium dioxide is used to absorb light, followed by a small amount of carbon black. This process absorbs light without affecting the fabric's original color, thus achieving an opaque effect.

[0101] Example 5

[0102] Reference Figure 1 Both warp core 11 and weft core 21 are white core wires. The PVC raw materials include dark PVC, plasticizer, antioxidant, heat stabilizer, flame retardant, and pigment. The dark PVC color can be black, etc. The first light-shielding layer 12 includes the following raw materials by weight fraction:

[0103]

[0104] In this embodiment, the PVC content is 52 parts, the plasticizer content is 28 parts, the stabilizer content is 1.3 parts, the titanium dioxide content is 7 parts, the pigment content is 0.2 parts, the flame retardant content is 8 parts, the carbon black content is 2 parts, and the additive content is 1.5 parts.

[0105] Raw material description:

[0106] PVC, Formosa Plastics Industrial (Ningbo) Co., Ltd., extrusion grade PVC;

[0107] Plasticizers, PVC plasticizers, Xingtianwai Chemical (Shanghai) Co., Ltd.;

[0108] Stabilizer, calcium-zinc stabilizer, BASF Chemical Co., Ltd.;

[0109] The titanium dioxide is rutile titanium dioxide with a TiO2 content of ≥96%, manufactured by Chemours Titanium Dioxide Technology.

[0110] Flame retardant, antimony trioxide, CAS number 1309-64-4, purity ≥99.5%;

[0111] Wollastonite powder, produced by Xinyu Nanfang Wollastonite Co., Ltd., is a white needle-like powder.

[0112] Examples 6-8

[0113] The difference between Examples 6-8 and Example 5 is that the amount of each component raw material used is different.

[0114] The specific details are shown in Table 4 below.

[0115] Table 4. Raw materials and dosage of the first light-shielding layer 12 (dosage unit: kg)

[0116]

[0117] Comparative Example 6

[0118] The difference between this comparative example and Example 8 is that wollastonite powder of equal mass is used instead of titanium dioxide.

[0119] Performance Test 2

[0120] The light-blocking performance of the light-blocking fabrics prepared in Examples 6-8 and Comparative Example 6 was tested. The testing method was the same as that in Example 1.

[0121] The experimental results are shown in Table 5 below.

[0122] Table 5 Results of the light-blocking test

[0123]

[0124]

[0125] As can be seen from the test results in Table 5, the curtain fabric prepared in this application has a complete light-blocking effect, thus achieving the effect of complete light blocking. In Examples 6 to 8, the amount of titanium dioxide remained constant, and the influence of changes in the amount of other components on the light-blocking degree of the blackout fabric was investigated. Among them, Example 8 is the preferred embodiment.

[0126] The working principle of this application embodiment is as follows:

[0127] By reflecting light with titanium dioxide and then absorbing light with carbon black, the amount of light passing through the weaving nodes is reduced. At the same time, by controlling the weaving density of warp 1 and weft 2, the first light-blocking layer 12 and the second light-blocking layer 22 are made to abut or press against each other, thus further reducing the probability of light passing through the weaving nodes and improving the light-blocking effect of the light-blocking cloth.

[0128] This application discloses a manufacturing method.

[0129] Reference Figure 1 and Figure 2 The manufacturing method includes the following steps:

[0130] Granulation Production: PVC raw materials, titanium dioxide, and carbon black are mixed and granulated in a certain proportion, and then extruded through a screw extruder to coat the warp core 11 and weft core 21, thereby forming the first light-shielding layer 12 and the second light-shielding layer 22, thus obtaining warp 1 and weft 2; Weaving: The warp 1 and weft 2 are woven using a weaving machine 3. During the weaving process, the weaving density of the warp 1 and weft 2 is controlled by controlling the tension of the warp 1 and weft 2 during the weaving process. The tension structure adopts a spring tensioning mechanism. The structure is tight, and both the rapier loom 3 and the tension structure are existing technologies, so they will not be described in detail here. Controlling the tension stretches the warp 1 and weft 2 during weaving, thus stretching the first light-blocking layer 12 and the second light-blocking layer 22. After weaving, the tension disappears, and the first and second light-blocking layers 12 and 22 rebound, causing their flat surfaces to press against each other, sealing the weaving nodes of the warp 1 and weft 2. This ensures that the weaving density of the warp 1 and weft 2 meets the weaving requirements. The mutual pressing of the flat surfaces of the first and second light-blocking layers 12 and 22 significantly reduces the gap between the warp 1 and weft 2.

[0131] Appropriate tension control allows the first light-blocking layer 12 and the second light-blocking layer 22 to be stretched without damaging them. Simultaneously, the rapier loom 3 is equipped with a temperature control absorption mechanism 4 and a cooling component 6. This controls the temperature of the first light-blocking layer 12 on the warp 1 and the second light-blocking layer 22 on the weft 2 during the weaving process, ensuring the PVC material reaches its optimal temperature. This reduces the impact of excessively high or low temperatures on the quality of the PVC material and improves its performance. Furthermore, the temperature control absorption mechanism 4 cleans dust from the warp 1 and weft 2, reducing the adverse effects of dust on weaving density control and improving the light-blocking effect of the blackout fabric.

[0132] Heat setting: The meridian 1 and the parallel 2 are heat set, so that the meridian 1 and the parallel 2 become flat.

[0133] Testing: The light transmittance of the blackout fabric is tested. The light-blocking degree of the blackout fabric is controlled through the above physical methods to achieve an opaque level; therefore, chemical experimental methods and data are not required here.

[0134] Reference Figure 1 and Figure 2 Cooling pipes 31 are installed on both sides of the weaving area of ​​multiple warp threads 1 and weft threads 2 on the rapier loom 3. An air inlet pipe 32 for inputting gas is fixedly installed on the cooling pipe 31. The air inlet pipe 32 is connected to the gas source and is used to control the pressure of the gas input. Gas is input into the air inlet pipe 32 and the weft threads 2 are output through the cooling pipe 31, thereby cooling the weft threads 2.

[0135] Reference Figure 2 and Figure 3 The cooling assembly 6 includes a housing 61, a control board 62, a control component 63, and a temperature detector 64. The housing 61 is fixedly installed on the rapier loom 3 and is filled with coolant. A gap is left between the coolant level and the top wall of the housing 61. At the same time, the air inlet pipe 32 passes horizontally through the opposite side walls of the housing 61 and the coolant.

[0136] The control board 62 is horizontally slidably installed inside the housing 61, and the air inlet pipe 32 is slidably inserted through the control board 62. At the same time, the control board 62 divides the housing 61 into a first space 65 and a second space 66. The first space 65 is located in the second space 66 on the side near the gas input of the air inlet pipe 32, and the coolant is stored in the first space 65. The control component 63 is an electric actuator, which is fixedly installed on the outer wall of the housing 61 on the side near the second space 66. The piston rod of the electric actuator is fixedly connected to the control board 62. When the electric actuator is activated, it drives the control board 62 to move. The movement of the control board 62 pushes the coolant to flow, thereby adjusting the length of the air inlet pipe 32 that is in contact with the coolant, so as to adjust the cooling effect of the gas in the air inlet pipe 32.

[0137] A control box for controlling the start and stop of the electric push rod is fixedly installed on the rapier loom 3. A temperature detector 64 is fixedly installed on the cooling pipe 31 and is used to detect the temperature of the gas entering the cooling pipe 31. At the same time, the temperature detector 64 is electrically connected to the control box. After detecting the temperature, the temperature detector 64 sends a signal to the control box, and the control box controls the start and stop of the electric push rod.

[0138] Reference Figure 2 and Figure 3 When the temperature detector 64 detects that the temperature is higher than the specified value, the temperature detector 64 triggers a signal to the control box. The control box controls the electric actuator to move the control board 62 closer to the second space 66, so that the contact length between the coolant and the air inlet pipe 32 is increased, thereby improving the cooling effect on the gas. When the temperature detector 64 detects that the temperature is lower than the specified value, the electric actuator starts to move the control board 62 in the opposite direction, so that the contact length between the coolant and the air inlet pipe 32 is shortened, thereby reducing the cooling effect on the gas and making the gas temperature inside the cooling pipe 31 appropriate. This keeps the second light-shielding layer 22 at an appropriate temperature and improves the light-shielding effect of the light-shielding cloth.

[0139] Reference Figure 2 and Figure 4 The temperature control absorption mechanism 4 includes an air outlet plate 41, an air intake plate 42, a cooling box 43, a fan 44, a filter assembly 45, and a temperature control assembly 5.

[0140] Reference Figure 1 and Figure 4The air outlet plate 41 and the air intake plate 42 are vertically and fixedly installed on the rapier loom 3. The air outlet plate 41 is located on the lower side of the multiple warp threads 1, while the air intake plate 42 is located on the upper side of the multiple warp threads 1. The upper surface of the air outlet plate 41 is provided with a long strip-shaped air outlet hole, while the lower surface of the air intake plate 42 is provided with a long strip-shaped air intake hole. At the same time, the length direction of the air outlet hole and the air intake hole is perpendicular to the moving direction of the multiple warp threads 1.

[0141] Reference Figure 2 and Figure 4 The cooling box 43 is fixedly installed on the side wall of the rapier loom 3, and the upper surface of the cooling box 43 is fixedly installed with an air suction pipe 431 that is fixedly connected to the upper surface of the air suction plate 42. The lower surface of the cooling box 43 is fixedly installed with an air outlet pipe 432 that is fixedly connected to the lower surface of the air outlet plate 41. At the same time, the air suction pipe 431 connects the cooling box 43 with the air suction hole, and the air outlet pipe 432 connects the air outlet with the cooling box 43.

[0142] The fan 44 is fixedly installed on the bottom wall of the cooling box 43. The filter assembly 45 and the temperature control assembly 5 are vertically spaced on the cooling box 43. The filter assembly 45 is located above the temperature control assembly 5, and the temperature control assembly 5 is located above the fan 44. The filter assembly 45 is used to filter and collect dust, and the temperature control assembly 5 is used to regulate the temperature of the gas.

[0143] Reference Figure 1 and Figure 4 When the fan 44 starts, the dust on the warp 1 and weft 2 rises. The dust then enters the cooling box 43 through the air intake and air intake pipe 431. The filter assembly 45 filters and collects the dust. The filtered gas is regulated by the temperature control assembly 5. The gas is blown onto multiple warp 1 through the air outlet pipe 432 and air outlet, so that the temperature of the first light-shielding layer 12 is within a suitable range, and the dust on multiple warp 1 and weft 2 is cleaned.

[0144] Reference Figure 4 A mounting hole is provided on the side wall of the cooling box 43 and above the fan 44. The filter assembly 45 includes a filter frame 46 and a mounting plate 47. The filter frame 46 is horizontally slidably installed on the mounting hole, and multiple filter holes for gas to pass through are evenly provided on the filter frame 46. The filter frame 46 filters and collects dust in the gas. The mounting plate 47 is fixedly installed on the side wall of the filter frame 46 and is positioned against the outer side wall of the cooling box 43.

[0145] The temperature control assembly 5 includes a cooling plate 51, a control tube 52, a control piston 53, a drive component 54, and a temperature detector 55. The cooling plate 51 is fixedly installed on the inner wall of the cooling box 43, and is located below the filter frame 46 and above the fan 44. The cooling plate 51 has multiple ventilation holes 56 that penetrate the upper and lower surfaces of the cooling plate 51 at intervals, and a cooling cavity 57 that is not connected to the ventilation holes 56 is opened on the inner wall of the cooling plate 51. The control tube 52 includes a horizontal section 521 and a vertical section 522 that are connected to each other. One end of the horizontal section 521 is fixedly installed on the side wall of the cooling plate 51 and extends horizontally out of the cooling box 43. At the same time, the horizontal section 521 is connected to the cooling cavity 57. The vertical section 522 is vertical and its top end is connected to the end of the horizontal section 521 located outside the cooling box 43.

[0146] The control piston 53 is vertically slidably mounted on the inner wall of the vertical section 522. The vertical section 522, the horizontal section 521, and the cooling chamber 57 are all filled with coolant. The vertical movement of the control piston 53 can control the amount of coolant in the cooling chamber 57. The driving component 54 is an electric cylinder, which is fixedly mounted on the bottom end of the vertical section 522. The piston rod of the electric cylinder is vertically upward and fixedly connected to the control piston 53, thereby driving the control piston 53 to move vertically, thereby adjusting the amount of coolant in the cooling chamber 57, and thus adjusting the cooling effect of the gas passing through the ventilation hole 56.

[0147] Reference Figure 4 The temperature detector 55 is fixedly installed on the side wall of the rapier loom 3, and the temperature detector 55 is used to detect the temperature of the warp 1. The temperature detector 55 is an infrared thermometer. The control box can also independently control the start and stop of the electric push cylinder. At the same time, after the temperature detector 55 detects the temperature, it triggers a signal to be sent to the control box, thereby realizing the start and stop of the electric push cylinder according to the temperature.

[0148] Reference Figure 1 and Figure 4When fan 44 starts, dust on warp 1 and weft 2 enters filter frame 46 through air intake hole and air intake pipe 431 for collection. Air is cooled through multiple ventilation holes 56 on cooling plate 51. Then, air is blown onto multiple warp 1 through air outlet pipe 432 and air outlet hole, thereby cooling the first light-shielding layer 12 on multiple warp 1 and cleaning the dust on warp 1 and weft 2. At the same time, temperature detector 55 detects the temperature on multiple warp 1. When the temperature is higher than a specified value, temperature detector 55 triggers. A signal is sent to the control box, which then controls the electric pusher cylinder to start, causing the control piston 53 to move upward. The control piston 53 pushes the coolant in the vertical section 522 into the cooling chamber 57, thereby increasing the amount of coolant in the cooling chamber 57 and improving the cooling effect on the gas, thus reducing the temperature of the first light-shielding layer 12. When the temperature is lower than the specified vertical position, the electric pusher cylinder moves downward, reducing the amount of coolant in the cooling chamber 57, thereby keeping the temperature of the first light-shielding layer 12 within the required range and improving the light-shielding effect of the light-shielding cloth.

[0149] The working principle of this application embodiment is as follows:

[0150] First, PVC raw materials, titanium dioxide, and carbon black are mixed and granulated in a certain proportion, and then coated onto warp core 11 and weft core 21 to obtain warp 1 and weft 2. Then, warp 1 and weft 2 are woven by a rapier loom 3. At the same time, the tension on warp 1 and weft 2 is controlled during weaving, so that the first light-blocking layer 12 and the second light-blocking layer 22 after weaving come into contact with or press against each other to seal the weaving nodes. At the same time, the temperature of warp 1 and weft 2 is controlled, and the dust on warp 1 and weft 2 is cleaned. Finally, the light transmittance of the fabric is tested using a light transmittance meter, thereby improving the light-blocking effect of the blackout fabric.

[0151] The gas is cooled by the coolant in the container 61, and then blown towards the weft yarn 2 for cooling and weft insertion, thereby controlling the temperature of the second light-shielding layer 22. At the same time, the fan 44 is started, causing the dust to move to the filter frame 46 for cleaning. Then the gas is cooled by the cooling plate 51 and blown towards the warp yarns 1 through the air outlet, thereby controlling the temperature of the first light-shielding layer 12 and cleaning the dust on the warp yarns 1 and weft yarns 2, thus improving the light-shielding effect of the light-shielding cloth.

[0152] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for manufacturing a light-blocking fabric, characterized in that: The fabric includes a warp (1) and a weft (2) formed with the warp (1) in a plain weave. The warp (1) includes a warp core (11) and a first light-shielding layer (12) covering the warp core (11). The weft (2) includes a weft core (21) and a second light-shielding layer (22) covering the weft core (21). The materials used to prepare the first light-shielding layer (12) and the second light-shielding layer (22) both include PVC, titanium dioxide and carbon black. The weaving density of the fabric is set according to the following formula: A1*W1≥25.4mm, and A2*W2+(A2-1)*W1≥25.4mm; Where A1 is the weaving density of the warp (1), A2 is the weaving density of the weft (2), W1 is the minimum width of the warp (1), W2 is the minimum width of the weft (2), and during weaving, the warp (1) passes between two adjacent wefts (2) and the two adjacent warp (1) abut or press against each other. The manufacturing method includes the following steps: Preparation of the first light-shielding layer (12) and the second light-shielding layer (22): Weigh various raw materials according to the proportion, and then mix the various raw materials to obtain the first light-shielding layer (12) and the second light-shielding layer (22). Preparation of warp (1) and weft (2): The first light-shielding layer (12) and the second light-shielding layer (22) are extruded by a screw and then wrapped on the warp core (11) and the weft core (21) respectively to obtain the warp (1) and the weft (2). Weaving: The warp (1) and weft (2) are woven into a fabric using a weaving device. During the weaving process, the weaving density of the warp (1) and weft (2) is controlled so that the weaving density of the warp (1) and weft (2) meets the weaving requirements. At the same time, the temperature of the warp (1) and weft (2) is controlled during the weaving process. Heat setting: heat setting the woven fabric; Testing: The light transmittance of the heat-set fabric is tested; The weaving equipment is a rapier loom (3). The rapier loom (3) is equipped with a cooling pipe (31) for cooling and controlling the temperature of the weft yarn (2). The rapier loom (3) is also equipped with a cooling component (6) and a temperature control absorption mechanism (4) connected to the cooling pipe (31). The cooling component (6) is used to cool the weft yarn (2). The temperature control absorption mechanism (4) absorbs dust on the warp yarn (1) and the weft yarn (2) and controls the temperature of the warp yarn (1). The temperature control absorption mechanism (4) includes: Air outlet plate (41), the air outlet plate (41) is set on the rapier loom (3) and located below the warp (1) and has an air blowing hole for blowing air upward; The suction plate (42) is installed on the rapier loom (3) and located above the warp (1) and has suction holes for gas and dust to enter; Cooling box (43), the cooling box (43) is installed on the rapier loom (3) and is provided with an air outlet pipe (432) and an air inlet pipe (431) respectively connected to the air blowing hole and the air inlet. A fan (44) is mounted on the cooling box (43) and causes gas to be blown out through the air outlet and enter through the air intake. A filter assembly (45) and a temperature control assembly (5) are provided on the cooling box (43) at intervals, so that the gas is filtered by the filter assembly (45) and then passed through the temperature control assembly (5) to achieve temperature control; The temperature control component (5) includes: Cooling plate (51), the cooling plate (51) is disposed in the cooling box (43) and has a plurality of ventilation holes (56) that pass through the cooling plate (51) evenly provided, and a cooling cavity (57) is provided in the cooling plate (51). The control tube (52) is mounted on the control board (62) and communicates with the cooling chamber (57), and both the control tube (52) and the cooling chamber (57) are filled with coolant. A control piston (53) is slidably mounted on a control tube (52) and moves to adjust the amount of coolant in the cooling chamber (57); A drive unit (54) is disposed on a control tube (52) and is used to drive the control piston (53) to move; Temperature detector (55), which is installed on the rapier loom (3) and used to detect the temperature of the warp (1) and is connected to the drive unit (54); The cooling pipe (31) is provided with an air inlet pipe (32) for introducing gas, and the cooling assembly (6) includes: A container (61) is mounted on a rapier loom (3) and contains coolant. An air inlet pipe (32) passes horizontally through the container (61) and the coolant, and the coolant cools the gas in the air inlet pipe (32). A control board (62) is slidably mounted in a housing (61) along the axis of the air inlet pipe (32) and is used to control the length of the air inlet pipe (32) in contact with the coolant; A control unit (63) is disposed on the housing (61) and connected to the control board (62) for driving the control board (62) to move; Temperature detector (64) is disposed on cooling pipe (31) and used to detect the temperature of gas entering cooling pipe (31) and is electrically connected to control unit (63).

2. The method for manufacturing a light-blocking fabric according to claim 1, characterized in that: Both the warp core (11) and the weft core (21) are black core threads, and the first light-shielding layer (12) comprises the following raw materials by weight fraction: Light-colored PVC, 50-52 parts; Plasticizer 21-25 parts; Heat stabilizer 1-1.5 parts; 5-6 parts flame retardant; 16-18 parts titanium dioxide; Pigment 0.2~0.4 parts; Carbon black 0.1~0.3 parts; Additives: 0.5 to 1.5 parts.

3. The method for manufacturing a light-blocking fabric according to claim 1, characterized in that: Both the warp core (11) and the weft core (21) are white cores, and the first light-shielding layer (12) comprises the following raw materials by weight fraction: Dark-colored PVC, 50-52 parts; Plasticizer 21-28 parts; Heat stabilizer 1-2.5 parts; 5-10 parts flame retardant; 6-8 parts titanium dioxide; Pigment 0.2~0.3 parts; 2-4 parts carbon black; Additives: 0.5 to 1.5 parts.

4. The method for manufacturing a light-blocking fabric according to claim 1, characterized in that: The filter assembly (45) includes: A filter frame (46) is horizontally slidably mounted on a cooling box (43) and is used to filter the gas and collect impurities. Mounting plate (47) is mounted on filter frame (46) and positioned against cooling box (43).

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