Knitted multi-layer hollow heterogeneous protective structure fabric and preparation method thereof

Abstract

The present application relates to a knitted multi-layer hollow heterogeneous protective structure fabric and its preparation method, and relates to the field of textiles. The knitted multi-layer hollow heterogeneous protective structure fabric prepared by the technical solution of the present application can be filled with protective blocks of different materials, can be assembled according to actual conditions, and the protective blocks are overlapped up and down, with fine slits on the left and right, which can effectively resist threats such as punctures and cuts; moreover, the protective blocks are not fixed, and a damaged protective block can be disassembled and replaced without damaging the main fabric, which is very suitable for some daily jobs that involve collisions and punctures; in addition, the knitted multi-layer hollow heterogeneous protective structure fabric only needs to be knitted and formed once by a multi-needle bed fully formed computer flat knitting machine and then flattened, which is simple in the back-end process, can improve production efficiency while having properties such as softness, flexibility, and machinability.

Description

Technical Field

[0001] The present application relates to the field of textile technology, and in particular to a knitted multi-layer hollow heterogeneous protective structure fabric and a preparation method thereof. Background Art

[0002] At present, many high-risk occupations are equipped with specific protective clothing to ensure the safety of the personnel themselves. For example, bodyguards, lumberjacks, shipyard cleaners and other occupations can be used to resist threats such as punctures and scratches in the working environment. Therefore, protective clothing for various scenarios is emerging in the market, and many research and development teams are also focusing on the development of related protective products. Protective clothing is divided into many types according to the application scenario, and the implementation methods are different. Among them, protective clothing that can cope with various impacts is particularly widely used and has a large market demand. In order to meet the performance requirements of this type of protective clothing, hard materials are an important part of the development that cannot be ignored. The selection of soft and comfortable fabrics combined with resin coating, hard particle attachment and other means to prepare composite materials with excellent protective properties is a common technical step in existing research.

[0003] In related technology, patent publication CN112659565A provides a novel method for preparing flexible, cut- and stab-resistant fabrics. This method uses 3D printing technology to print a shaped sheet of hard material onto a substrate. The sheet is then bonded to the fabric surface using a thermosetting resin adhesive. The resulting cured fabric is soft, comfortable, and offers puncture and cut resistance. Patent publication CN116499310A provides a multifunctional stab-resistant garment. This material is blended and modified with a modifier and ultra-high molecular weight polyethylene, which is then combined with aramid fibers to form a non-woven fabric. This fabric is then laminated to create a stab-resistant material with antistatic and flame-retardant properties.

[0004] However, although the methods mentioned in the above-mentioned related technologies can improve the protective performance of the materials, these means inevitably have to go through very complicated, tedious and lengthy processes to combine the hard protective materials with the base fabric to achieve the protective effect, which will seriously limit the production efficiency and there will be a problem of poor bonding. At the same time, once combined, it is basically irremovable, which is also a disadvantage for some occupations that use it as daily work clothes. Summary of the Invention

[0005] The purpose of this application is to provide a knitted multi-layer hollow heterogeneous protective structure fabric and a preparation method thereof to solve the problems existing in the above-mentioned prior art.

[0006] To achieve the above objectives, the technical solutions adopted in this application are:

[0007] In a first aspect, the present application provides a knitted multi-layer hollow heterogeneous protective structure fabric, wherein the fabric is knitted and formed once by a multi-needle bed fully formed computer flat knitting machine and then flat-pressed to form an array of stacked bag-shaped multi-layer hollow heterogeneous protective structures, wherein the minimum cyclic organizational unit of the multi-layer hollow heterogeneous protective structure includes a base fabric, a first hollow layer, and a second hollow layer;

[0008] The base fabric and the first hollow layer are two layers of knitted loops formed by knitting spacer loops on the front and rear needle beds, respectively; the second hollow layer is knitted with a new row of loops by the empty needles of the needle bed, and then the loops of the two adjacent rows of needle beds are separated from each other by turning the needles back and forth, without interlacing, to form the second hollow layer in layers;

[0009] Protection blocks can be detachably installed in both the first hollow layer and the second hollow layer. The protection blocks in the first hollow layer and the second hollow layer are staggered and partially overlapped.

[0010] In a second aspect, the present application provides a method for preparing a knitted multi-layer hollow heterogeneous protective structure fabric, which is applicable to the knitted multi-layer hollow heterogeneous protective structure fabric as described above, and the method comprises:

[0011] S1. Weaving the first row of the knitted multi-layer hollow heterogeneous protective structure fabric:

[0012] S11, feeding the first yarn into a yarn mouth No. 1 of a multi-needle bed computerized flat knitting machine to weave the base fabric, the first hollow layer, and the main body of the second hollow layer;

[0013] S12, feeding the second yarn into the second yarn feeder of the multi-needle bed computerized flat knitting machine to participate in knitting the openings of the first hollow layer and the second hollow layer;

[0014] S13, knitting spacer loops on the front and rear needle beds of the multi-needle bed computerized flat knitting machine, and ensuring that the front and rear needle bed loops are not connected, thereby forming two layers of knitted loops, namely the base fabric and the first hollow layer;

[0015] S14, the loops on the front needle bed are turned over to the empty needles on the rear needle bed, and a new row of loops is knitted on the empty needles on the front needle bed. Then the loops turned over to the empty needles on the rear needle bed are turned back to the front needle bed, so that the spacer loops on the two adjacent rows of loops on the front needle bed are separated from each other and do not interlace. After the loops are removed from the machine, the spacer loops on the front needle bed will be layered to form a third layer of knitted loops, i.e., the second hollow layer.

[0016] S2, weaving the second row of the knitted multi-layer hollow heterogeneous protective structure fabric:

[0017] S21, based on the upper surface of the second hollow layer, the loops on the needles on the front needle bed are transferred back and forth to the empty needles on the rear needle bed to perform the knitting method of the above steps S11 to S14; wherein, the first yarn is knitted for a preset length without transfer, so that the multi-layer knitted loops are interlaced and connected with each other, and the first yarn is knitted for a preset width and is transferred back and forth obliquely to form a multi-row overlapping hollow heterogeneous protective structure;

[0018] S3, after repeating steps S1 and S2 several times, a preliminary knitted multi-layer hollow heterogeneous protective structure fabric is obtained;

[0019] S4. Flatten the preliminary knitted multi-layer hollow heterogeneous protective structure fabric to completely dissolve the second yarn, and detachably install protective blocks in the first hollow layer and the second hollow layer to obtain the final knitted multi-layer hollow heterogeneous protective structure fabric.

[0020] In a possible implementation, the method uses a double-needle-bed fully-fashioned computerized flat knitting machine for weaving, and the first yarn uses ultra-high molecular weight polyethylene yarn.

[0021] In a possible implementation, the second yarn is 30° C. water-soluble yarn.

[0022] In a possible implementation, step S4 includes:

[0023] The preliminary knitted multi-layer hollow heterogeneous protective structure fabric is treated under low-temperature pressing at a temperature of 30°C and a humidity of 85% for 1 hour to completely dissolve the 30°C water-soluble yarn. After removably installing protective blocks in the first hollow layer and the second hollow layer, the final knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

[0024] In a possible implementation, the method uses a four-needle-bed fully-fashioned computerized flat knitting machine for weaving, and the first yarn uses aramid yarn.

[0025] In a possible implementation, the second yarn is made of 80°C hot melt yarn.

[0026] In a possible implementation, step S4 includes:

[0027] The preliminary knitted multi-layer hollow heterogeneous protective structure fabric is ironed by a 150°C ironing machine to completely dissolve the 80°C hot melt wire. After the protective blocks are detachably installed in the first hollow layer and the second hollow layer, the final knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

[0028] In a possible implementation, the protective block is made of a 3k carbon fiber resin plate or a pure resin plate.

[0029] In a possible implementation, the mesh count of the first yarn is 800D.

[0030] The beneficial effects of the technical solution provided by this application include at least:

[0031] The knitted multi-layer hollow heterogeneous protective structure fabric prepared by the technical solution of the present application can be filled with protective blocks of different materials and can be assembled according to actual conditions. The protective blocks are overlapped up and down, and have fine gaps on the left and right, which can effectively resist threats such as punctures and cuts. Moreover, the protective blocks are not fixed. A damaged protective block can be removed and replaced without damaging the main fabric, which is very suitable for some daily jobs involving collisions and punctures. In addition, the knitted multi-layer hollow heterogeneous protective structure fabric only needs to be woven and formed once by a multi-needle bed fully formed computer flat knitting machine and then flat pressed. The subsequent process is simple, which can improve production efficiency while having properties such as softness, flexibility, and machinability. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings are used to provide a further understanding of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application. In the accompanying drawings:

[0033] Figure 1 A schematic structural diagram of a knitted multi-layer hollow heterogeneous protective structural fabric provided by an exemplary embodiment of the present application is shown;

[0034] Figure 2 A simulation diagram of the overall structure of a knitted multi-layer hollow heterogeneous protective structural fabric provided by an exemplary embodiment of the present application is shown;

[0035] Figure 3 A schematic flow chart of a method for preparing a knitted multi-layer hollow heterogeneous protective structure fabric provided by an exemplary embodiment of the present application is shown;

[0036] Figure 4 A minimum cycle organization unit process diagram of a knitted multi-layer hollow heterogeneous protective structure fabric provided by an exemplary embodiment of the present application is shown;

[0037] Figure 5 A schematic diagram of the first row of three knitted hollow layers and the second row of three knitted hollow heterogeneous structures of a knitted multi-layer hollow heterogeneous protective structure fabric provided by an exemplary embodiment of the present application is shown. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0039] Among them, the same parts are represented by the same figure marks. It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to the directions in the drawings of the present application specification, and the words "bottom" and "top", "inside" and "outside" refer to directions toward or away from specific parts, respectively. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present application specification, the meaning of "multiple" is two or more.

[0040] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0041] Example 1:

[0042] Figure 1 The figure shows a schematic structural diagram of a knitted multi-layer hollow heterogeneous protective structural fabric provided by an exemplary embodiment of the present application. Figure 2 A simulation diagram of the overall structure of a knitted multi-layer hollow heterogeneous protective structure fabric provided by an exemplary embodiment of the present application is shown. The fabric is knitted and formed once using a multi-needle-bed fully formed computerized flat knitting machine, and then flattened to form an array of stacked, bag-shaped, multi-layer hollow heterogeneous protective structures. The minimum recurring organizational unit of the multi-layer hollow heterogeneous protective structure includes a base fabric 1, a first hollow layer 2, and a second hollow layer 3. The base fabric 1 and the first hollow layer 2 are two layers of knitted loops formed by knitting spacer loops on the front and rear needle beds, respectively. The second hollow layer 3 is knitted with a new row of loops using the empty needles of the needle beds. The loops are then transferred back and forth to separate the loops in the two adjacent rows of needle beds from each other, preventing them from interlacing, and forming the second hollow layer 3 in layers. Protective blocks 4 are removably installed in both the first and second hollow layers 2 and 3, and the protective blocks 4 in the first and second hollow layers 2 and 3 are interlaced and partially overlapped.

[0043] Optionally, the fabric can be unraveled by dissolving, melting, or disassembling the yarns, creating an array of stacked, open knitted bags. Protective blocks can be inserted to act as the fabric's protective material. Furthermore, the protective blocks can be filled with different materials and sizes to protect against threats like punctures and cuts, and can be removed and replaced if damaged. Furthermore, the fabric's manufacturing process can be adjusted based on the protection scenario and the size of the protective blocks, ensuring that the protective blocks overlap vertically and have fine seams on the left and right.

[0044] Optionally, the protective block includes but is not limited to a 3k carbon fiber resin plate or a pure resin plate.

[0045] Example 2:

[0046] Figure 3 A schematic flow chart of a method for preparing a knitted multi-layer hollow heterogeneous protective structure fabric provided by an exemplary embodiment of the present application is shown. The method is applicable to the knitted multi-layer hollow heterogeneous protective structure fabric as described in Example 1. The method comprises the following steps:

[0047] Step S1, knitting the first row of the multi-layer hollow heterogeneous protective structure fabric:

[0048] In this embodiment, if Figure 1 、 Figure 2 As shown, the fabric is shaped like an assembleable pocket and is constructed of three layers of knitted base fabric, including a base fabric 1, a first hollow layer 2 and a second hollow layer 3. It is woven into a pattern in one go using the machine's needle turning technology and spacer knitting method, revealing an array of open knitted fabric bags. Protective blocks are inserted to act as protective materials for the fabric, thereby achieving a protective effect for the fabric.

[0049] Step S11: feeding the first yarn into the No. 1 yarn feeder of the multi-needle bed computerized flat knitting machine to weave the base fabric, the first hollow layer and the main body of the second hollow layer.

[0050] Step S12: feeding the second yarn into the No. 2 yarn feeder of the multi-needle bed computerized flat knitting machine to participate in knitting the openings of the first hollow layer and the second hollow layer.

[0051] Step S13: knitting spacer loops on the front and rear needle beds of the multi-needle bed computerized flat knitting machine, and ensuring that the front and rear needle bed loops are not connected, thereby forming two layers of knitted loops, namely the base fabric and the first hollow layer.

[0052] Step S14, the coils hanging on the front needle bed are turned over to the empty needles of the rear needle bed. At this time, a new row of coils is knitted on the empty needles of the front needle bed, and then the coils turned over to the empty needles of the rear needle bed are turned back to the front needle bed, so that the spacer coils of the two adjacent rows of front needle bed coils are separated from each other without interlacing. After being taken off the machine, the spacer coils of the front needle bed will be layered to form a third layer of knitted coils, that is, the second hollow layer.

[0053] In this embodiment, the above steps S13 to S14 are described in detail. Figure 4 The minimum cycle organizational unit process diagram of the knitted multi-layer hollow heterogeneous protective structure fabric is shown.

[0054] Step S2: weaving the second row of the knitted multi-layer hollow heterogeneous protective structure fabric:

[0055] Step S21, based on the upper surface of the second hollow layer, the coils on the needles on the front needle bed need to be turned back and forth on the empty needles on the rear needle bed to perform the knitting method of the above steps S11 to S14; wherein, the first yarn is knitted at a preset length without turning, so that the multi-layer knitted coils are intertwined and connected with each other, and the first yarn is knitted at a preset width and turned back and forth obliquely to form a multi-row overlapping hollow heterogeneous protective structure.

[0056] In this embodiment, please refer to the above step S21. Figure 5 The diagram shows the first row of three-layer knitted hollow and the second row of three-layer knitted hollow heterogeneous structures of the knitted multi-layer hollow heterogeneous protective structure fabric.

[0057] Step S3: After repeating steps S1 and S2 several times, a preliminary knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

[0058] Step S4: Flatten the preliminarily knitted multi-layer hollow heterogeneous protective structure fabric to completely dissolve the second yarn, and detachably install protective blocks in the first hollow layer and the second hollow layer to obtain the final knitted multi-layer hollow heterogeneous protective structure fabric.

[0059] It should be noted that the first yarn of this method is 800D ultra-high molecular weight polyethylene yarn (UHMWPE), and the second yarn is 30°C water-soluble yarn, which are prepared on a 7.2-needle double-needle bed fully fashioned Stoll computer flat knitting machine (CMS 530 Karl Mayer - Germany).

[0060] In this embodiment, 30℃ water-soluble yarn is selected to participate in local weaving. On the one hand, it is convenient for machine weaving to form, and the upper and lower yarns can be trapped during weaving, which is convenient for the machine to weave continuously and hold the coils without curling; on the other hand, it is so that after the machine is off, it can be dissolved to form an opening during low-temperature finishing of ultra-high molecular weight polyethylene yarn. The water-soluble yarn is completely dissolved in the 30℃ water environment after the weaving machine is off.

[0061] In this embodiment, 3k carbon fiber resin plate is selected to act as the protective block of the fabric, such as Figure 2 As shown, its knitted loops will catch the protective block to prevent it from slipping or falling.

[0062] Furthermore, the above-mentioned step S4 specifically includes: treating the preliminary knitted multi-layer hollow heterogeneous protective structure fabric under low-temperature pressing at a temperature of 30°C and a humidity of 85% for 1 hour to completely dissolve the 30°C water-soluble yarn, and after detachably installing a 3k carbon fiber resin plate in the first hollow layer and the second hollow layer, obtaining the final knitted multi-layer hollow heterogeneous protective structure fabric.

[0063] Example 3:

[0064] The preparation method of the knitted multi-layer hollow heterogeneous protective structure fabric provided in this embodiment is basically the same as that in the second embodiment, except that:

[0065] In this embodiment, MACH2XSI53-12G Shima Seiki four-needle bed fully fashioned computerized flat knitting machine was selected to prepare the protective fabric.

[0066] In this embodiment, the first yarn is 800D aramid and the second yarn is 80°C hot melt yarn.

[0067] In this embodiment, corresponding to step S4 in Example 2, the preliminary knitted multi-layer hollow heterogeneous protective structure fabric is ironed by a 150°C ironing machine to completely dissolve the 80°C hot melt wire. After the pure resin plate is detachably installed in the first hollow layer and the second hollow layer, the final knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

[0068] To sum up, the knitted multi-layer hollow heterogeneous protective structure fabric prepared by the technical solution of the present application can be filled with protective blocks of different materials, can be assembled according to actual conditions, and the protective blocks are overlapped up and down, with fine gaps on the left and right, which can effectively resist threats such as stabbing and cuts; and the protective block is not fixed. Without damaging the main fabric, a damaged protective block can be removed and replaced, which is very suitable for some daily jobs that involve collisions and stabbings; in addition, the knitted multi-layer hollow heterogeneous protective structure fabric only needs to be woven and formed once by a multi-needle bed fully formed computer flat knitting machine and then flat pressed. The subsequent process is simple, which can improve production efficiency while having properties such as softness, flexibility, and machinability.

[0069] The above is only a preferred embodiment of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A method for preparing a knitted multi-layer hollow heterogeneous protective structure fabric, characterized in that: The method comprises the steps of: S1. Weaving the first row of the knitted multi-layer hollow heterogeneous protective structure fabric: S11, feeding the first yarn into a yarn mouth No. 1 of a multi-needle bed computerized flat knitting machine to weave the base fabric, the first hollow layer, and the main body of the second hollow layer; S12, feeding the second yarn into the second yarn feeder of the multi-needle bed computerized flat knitting machine to participate in knitting the openings of the first hollow layer and the second hollow layer; S13, knitting spacer loops on the front and rear needle beds of the multi-needle bed computerized flat knitting machine, and ensuring that the front and rear needle bed loops are not connected, thereby forming two layers of knitted loops, namely the base fabric and the first hollow layer; S14, the loops on the front needle bed are turned over to the empty needles on the rear needle bed, and a new row of loops is knitted on the empty needles on the front needle bed. Then the loops turned over to the empty needles on the rear needle bed are turned back to the front needle bed, so that the spacer loops on the two adjacent rows of loops on the front needle bed are separated from each other and do not interlace. After the loops are removed from the machine, the spacer loops on the front needle bed will be layered to form a third layer of knitted loops, i.e., the second hollow layer. S2, weaving the second row of the knitted multi-layer hollow heterogeneous protective structure fabric: S21, based on the upper surface of the second hollow layer, the loops on the needles on the front needle bed are transferred back and forth to the empty needles on the rear needle bed to perform the knitting method of the above steps S11 to S14; wherein, the first yarn is knitted for a preset length without transfer, so that the multi-layer knitted loops are interlaced and connected with each other, and the first yarn is knitted for a preset width and is transferred back and forth obliquely to form a multi-row overlapping hollow heterogeneous protective structure; S3, after repeating steps S1 and S2 several times, a preliminary knitted multi-layer hollow heterogeneous protective structure fabric is obtained; S4. Flatten the preliminary knitted multi-layer hollow heterogeneous protective structure fabric to completely dissolve the second yarn, and detachably install protective blocks in the first hollow layer and the second hollow layer to obtain the final knitted multi-layer hollow heterogeneous protective structure fabric.

2. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 1, characterized in that: The method adopts a double-needle-bed fully formed computerized flat knitting machine for weaving, and the first yarn adopts ultra-high molecular weight polyethylene yarn.

3. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 2, characterized in that: The second yarn is 30° C. water-soluble yarn.

4. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 3, characterized in that: The step S4 comprises: The preliminary knitted multi-layer hollow heterogeneous protective structure fabric is treated under low-temperature pressing at a temperature of 30°C and a humidity of 85% for 1 hour to completely dissolve the 30°C water-soluble yarn. After removably installing protective blocks in the first hollow layer and the second hollow layer, the final knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

5. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 1, characterized in that: The method adopts a four-needle-bed fully-fashioned computerized flat knitting machine for weaving, and the first yarn adopts aramid yarn.

6. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 5, characterized in that: The second yarn is made of 80°C hot melt yarn.

7. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 6, characterized in that: The step S4 comprises: The preliminary knitted multi-layer hollow heterogeneous protective structure fabric is ironed by a 150°C ironing machine to completely dissolve the 80°C hot melt wire. After the protective blocks are detachably installed in the first hollow layer and the second hollow layer, the final knitted multi-layer hollow heterogeneous protective structure fabric is obtained.

8. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 1, characterized in that: The protective block is made of 3k carbon fiber resin plate or pure resin plate.

9. The method for preparing the knitted multi-layer hollow heterogeneous protective structure fabric according to claim 1, characterized in that: The mesh number of the first yarn is 800D.

10. The knitted multi-layer hollow heterogeneous protective structural fabric prepared by the method according to any one of claims 1 to 9, characterized in that: The fabric is knitted once by a multi-needle bed fully formed computerized flat knitting machine and then flat-pressed to form an array-stacked bag-shaped multi-layer hollow heterogeneous protective structure, wherein the minimum circular organizational unit of the multi-layer hollow heterogeneous protective structure includes a base fabric, a first hollow layer, and a second hollow layer; The base fabric and the first hollow layer are two layers of knitted loops formed by knitting spacer loops on the front and rear needle beds, respectively; the second hollow layer is knitted with a new row of loops by the empty needles of the needle bed, and then the loops of the two adjacent rows of needle beds are separated from each other by turning the needles back and forth, without interlacing, to form the second hollow layer in layers; Protection blocks can be detachably installed in both the first hollow layer and the second hollow layer. The protection blocks in the first hollow layer and the second hollow layer are staggered and partially overlapped.

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