Flame-retardant braid and braiding process thereof

Abstract

The present application relates to the technical field of flame-retardant braid manufacturing technology, and particularly relates to a weaving process of flame-retardant braid, which comprises the following steps: S1, a weaving process; S2, a dip-dyeing process; S3, a first identification process; S4, a first brushing process; S5, a drying process; S6, a second identification process; S7, a second brushing process; S8, a secondary drying process; and S9, a detection process. In the present application, the natural material fiber with a rough surface is wound on the surface of the primary weaving sub-thread which is woven by flame-retardant material fiber, so that the surface of the final woven braid base is rougher, the interfacial adhesion between the woven base and the flame-retardant liquid is increased, and the flame-retardant liquid is dipped into the woven base through the dip-dyeing process, so that the woven flame-retardant braid has good tensile strength and better adhesion.

Description

Technical Field

[0001] This invention relates to the field of flame-retardant webbing manufacturing technology, and in particular to a flame-retardant webbing and its weaving process. Background Technology

[0002] Flame-retardant webbing refers to webbing made of flame-retardant fibers through a special process. This product has stable flame-retardant effect, is not easy to ignite, extinguishes itself when the flame is removed, and is permanently flame-retardant.

[0003] The existing flame-retardant webbing weaving process often uses a single flame-retardant fiber material for weaving, such as flame-retardant polyester fiber material or flame-retardant polyamide fiber material. Although it has high strength and elasticity, giving it higher tensile strength and wear resistance, it also makes its surface relatively smooth, with poor moisture absorption and lack of adhesion to flame retardants. It is not easy to be impregnated and dyed. On the other hand, if it is simply woven with easily impregnated natural fiber materials and flame retardant sprayed, it is difficult to guarantee its overall durability.

[0004] Chinese Patent Publication No. CN105133324B discloses an ultra-high molecular weight polyethylene flame-retardant braided tape and its preparation method. This flame-retardant braided tape uses ultra-high molecular weight polyethylene fibers as the tape body material to increase the tensile strength and abrasion resistance of the tape body. Furthermore, it enhances the flame-retardant effect by coating the tape with a latex coating to increase the interfacial adhesion between the tape and the flame-retardant liquid. Therefore, the existing flame-retardant tape and its weaving process have the following problems: when using only a single commercially available flame-retardant material as the tape body material, it is difficult to ensure that the woven tape possesses both good tensile strength and abrasion resistance while also having good adhesion to enhance the coating effect between the flame-retardant liquid and the tape, thus improving its flame-retardant ability. Summary of the Invention

[0005] Therefore, the present invention provides a flame-retardant webbing and its weaving process to overcome the problem that flame-retardant webbing woven with flame-retardant fiber materials in the prior art has poor cross-sectional adhesion, thus affecting its flame-retardant effect.

[0006] To achieve the above objectives, the present invention provides a weaving process for flame-retardant webbing, comprising:

[0007] Step S1, weaving process: using preset weaving process parameters, natural material fibers are woven around the primary weaving thread to obtain a secondary weaving thread with the natural material fibers wrapped on its surface. The secondary weaving thread is then woven to form the desired webbing base.

[0008] The preset weaving process parameters include the weaving pitch and the number of natural material fibers involved.

[0009] Step S2, dyeing process: The webbing substrate is introduced into a flame-retardant dyeing tank, and the flame-retardant liquid in the flame-retardant dyeing tank is used to dye the entire webbing substrate.

[0010] Step S3, the first identification process, involves real-time image acquisition of the webbing substrate after the dyeing process is completed by the first identification and determination device, and real-time adhesion rate is calculated based on the real-time image acquisition results. The real-time adhesion rate of the webbing substrate is determined by the standard adhesion rate to determine whether the weaving pitch of the natural material fiber should be adjusted.

[0011] Step S4, the first coating process, determines whether to perform flame retardant spraying operation on the dyed webbing substrate through the first coating device based on the judgment result of step S3.

[0012] Step S5, drying process, the webbing base is dried by the first drying device at a preset drying wind speed;

[0013] Step S6, the second identification process, the second identification and determination device performs a second real-time image acquisition on the webbing substrate that has completed the drying process, and calculates the real-time bareness rate of the webbing substrate based on the results of the second real-time image acquisition. The real-time bareness rate of the webbing substrate is determined based on the preset bareness rate to determine whether the drying wind speed of the first drying device should be adjusted.

[0014] Step S7, the second coating process, involves using a second coating device to perform a second spraying operation of flame retardant liquid on the webbing substrate that needs adjustment after being identified in step S6.

[0015] Step S8, secondary drying process, the webbing substrate after being coated in step S7 is dried a second time using a second drying device. If the webbing substrate has not been processed in step S7, it proceeds directly to step S9.

[0016] In step S9, the inspection process, the flame-retardant webbing that has been produced is weighed using a weighing device to obtain the real-time weight per meter of the flame-retardant webbing. Based on the standard weight per meter of the webbing, the real-time weight per meter of the flame-retardant webbing is determined to decide whether the amount of natural material fiber involved should be adjusted.

[0017] Further, in step S1, the following is included:

[0018] Step S101: Several flame-retardant material fibers are woven into primary braided sub-threads through the first weaving process;

[0019] Step S102: The output end of the first-level braided sub-thread completed in the first braiding process is fed into the second braiding process in real time, and the natural material fibers are braided around the first-level braided sub-thread using preset braiding process parameters to obtain a second-level braided sub-thread with natural material fibers wrapped around its surface.

[0020] Step S103: The secondary braiding sub-threads output from the second braiding process are fed into the third braiding process in real time to braid the secondary braiding sub-threads into the webbing base.

[0021] Furthermore, in step S3, a standard color value and a standard color fluctuation difference value for the flame retardant liquid are set, and a judgment range is formed based on the standard color value and the standard color fluctuation difference value.

[0022] In step S3, the real-time image of the webbing substrate acquired by the first identification and determination device is divided into several regions. The color value of each pixel in any region is obtained, and the average value of the color values ​​of each pixel in that region is calculated as the marker color value of that region.

[0023] The marking color values ​​of each zone in the real-time image of the webbing substrate are marked according to the judgment range formed by the difference between the standard color value and the standard color fluctuation value.

[0024] If the color value of any partition is within the judgment range, then the partition is marked as the attachment area;

[0025] If the color value of any partition is outside the judgment range, then that partition will not be marked.

[0026] Further, in step S3, the total area of ​​the real-time image of the webbing substrate is obtained by the first identification and determination device, and the total area of ​​all partitions with attachment area markings in the real-time image is obtained according to the partition marking result of the real-time image. The real-time attachment rate of the current webbing substrate is calculated based on the total area of ​​the real-time image and the total area of ​​all partitions with attachment area markings.

[0027] Where Fs = S1 / S, Fs is the real-time attachment rate, S1 is the total area of ​​all regions with attachment area markers in the real-time image, and S is the total area of ​​the real-time image.

[0028] Furthermore, in step S3, a standard adhesion rate is also set. After the first identification and determination device finishes calculating the real-time adhesion rate, the real-time adhesion rate is compared with the standard adhesion rate.

[0029] If the real-time adhesion rate is less than the standard adhesion rate, the weaving pitch in step S1 will be adjusted according to the real-time adhesion rate and the standard adhesion rate.

[0030] Furthermore, when the real-time adhesion rate of the webbing substrate is less than the standard adhesion rate, the weaving pitch parameter of the natural material fiber in step S1 will be obtained, and the weaving pitch parameter of the natural material fiber will be corrected according to the real-time adhesion rate and the standard adhesion rate.

[0031] Where Q'=Q×[1+(Fb-Fs) / Fb], Q' is the corrected weaving pitch of the natural material fiber, Q is the weaving pitch of the natural material fiber in the current weaving process, Fb is the set standard adhesion rate, and Fs is the real-time adhesion rate.

[0032] Further, in step S6, a current color fluctuation difference value is set to determine the current color value of the webbing substrate, the standard color value of the natural material fiber and the standard color value of the flame-retardant material fiber are obtained, and the exposed color range of the natural material fiber and the exposed color range of the flame-retardant material fiber are calculated respectively based on the standard color values ​​of the natural material fiber and the standard color values ​​of the flame-retardant material fiber.

[0033] Wherein, Yb1=Yb-ΔY, Yb2=Yb+ΔY, Ya1=Ya-ΔY, Ya2=Ya+ΔY, Yb is the standard color value of natural material fiber, Ya is the standard color value of flame retardant material fiber, ΔY is the current color fluctuation difference, Yb1 is the minimum value of the exposed color range of natural material fiber, Yb2 is the maximum value of the exposed color range of natural material fiber, Ya1 is the minimum value of the exposed color range of flame retardant material fiber, and Ya2 is the maximum value of the exposed color range of flame retardant material fiber;

[0034] The second identification and determination device performs secondary real-time image acquisition on the webbing substrate, extracts the real-time color value of the secondary real-time image, determines the image area of ​​the real-time color value in the secondary real-time image within the exposed color range of natural material fiber as the first exposed area, and determines the image area of ​​the real-time color value within the exposed color range of flame retardant material fiber as the second exposed area, and calculates the real-time exposed rate based on the total image area of ​​the acquired secondary real-time image.

[0035] Where Ls=(S1+S2) / Sz, S1 is the first exposed area, S2 is the second exposed area, Sz is the total area of ​​the secondary real-time image, and Ls is the real-time exposed area rate.

[0036] The real-time bare leakage rate is compared with the standard bare leakage rate.

[0037] If the real-time leakage rate is greater than the standard leakage rate, it is determined that there is a defect in the webbing substrate at the current position, and the real-time drying air speed in step S5 is adjusted according to the real-time leakage rate and the standard leakage rate.

[0038] Furthermore, when the real-time bare leakage rate of the webbing substrate is greater than the standard bare leakage rate, the drying wind speed parameter of the first drying device in step S5 will be obtained, and the drying wind speed parameter of the first drying device will be corrected according to the real-time bare leakage rate and the standard bare leakage rate.

[0039] Where V'=V×(Lb / Ls), V' is the corrected drying air velocity of the first drying device, V is the current drying air velocity of the first drying device, Lb is the set standard leakage rate, and Ls is the real-time leakage rate.

[0040] Furthermore, in step S9, the real-time weight of the webbing detected by the weighing device is determined in real time according to the set standard weight per meter of the webbing. If the real-time weight per meter of the webbing detected by the weighing device is greater than the standard weight per meter of the webbing, it is determined that the current weight of the flame-retardant webbing itself is defective, and the amount of natural material fiber involved in step S1 is adjusted according to the real-time weight per meter of the webbing and the standard weight per meter of the webbing.

[0041] Where N' = NN × (Gs - Gb) / Gb, N' is the corrected number of natural material fibers involved, N is the preset number of natural material fibers involved, Gb is the set standard webbing weight per meter, Gs is the real-time webbing weight per meter, and when N × (Gs - Gb) / Gb is less than 1, it is automatically corrected to 1;

[0042] If the real-time weight per meter of the webbing is less than or equal to the weight per meter of the standard webbing, it is determined that the weight of the current flame-retardant webbing is normal, and the output end of the current flame-retardant webbing is passed into the winding and sealing device for sealing and output.

[0043] Another aspect of the present invention provides a flame-retardant webbing produced based on any one of the above-mentioned flame-retardant webbing weaving processes, comprising,

[0044] The flame-retardant material fibers, the natural material fibers, and the flame-retardant layer formed by impregnation and coating with flame-retardant liquid,

[0045] The flame-retardant material fiber includes one or more of flame-retardant polyester fiber, flame-retardant nylon fiber, and halogen-free flame-retardant polyester fiber.

[0046] The natural material fibers include one or more of cotton fibers, hemp fibers, and silk fibers;

[0047] The flame retardant liquid composition includes one or more of halogenated flame retardants, phosphorus-based flame retardants, and inorganic flame retardants.

[0048] Compared with the prior art, the beneficial effects of the present invention are as follows: by winding relatively rough natural material fibers onto the surface of the primary braided sub-thread woven from flame-retardant material fibers, the surface of the final woven webbing base is made rougher, thereby increasing the interfacial adhesion between the braided base and the flame-retardant liquid. The flame-retardant liquid is then impregnated into the woven base through a dyeing process, resulting in a flame-retardant webbing with both good tensile strength and good adhesion, enhancing the coating effect between the flame-retardant liquid and the webbing, thus improving its flame-retardant ability. The dyed webbing base is assessed and corrected through a first identification process and a drying process. While adjusting the real-time weaving process, the dyed webbing base is also corrected. The initially dried webbing base is assessed and corrected through a second identification process and a secondary drying process to compensate for any defects in the flame-retardant webbing after drying. Finally, the final output flame-retardant webbing is assessed and corrected through a testing process, ensuring that the final output flame-retardant webbing has a good flame-retardant effect while reducing its overall weight for convenient subsequent real-time use.

[0049] Furthermore, by progressively dividing the weaving process into a first weaving process, a second weaving process, and a third weaving process, each weaving process can be carried out in an orderly and gradual manner. In the second weaving process, natural material fibers can be wrapped around the outer surface of each first-level weaving thread, making the surface of the resulting second-level weaving thread rougher. As a result, the webbing base woven from the second-level weaving thread has the tensile strength of flame-retardant material fibers while also having the adhesive force of natural material fibers on its surface.

[0050] In particular, the first coating process corrects the coating of the webbing substrate that needs to be coated after determination. That is, when the first identification process determines that the real-time adhesion rate of the current webbing substrate is less than the standard adhesion rate, it means that the current webbing substrate’s dyeing degree cannot meet the required standard. Therefore, the first coating device is needed to make up for and correct the dyed webbing substrate, so as to prevent substandard dyed webbing substrates from flowing to the next process.

[0051] Furthermore, the webbing substrate introduced into the drying device is dried by heating wires installed in the drying device, and the drying rate is accelerated by introducing drying air at the same temperature into the drying device to prevent undried webbing substrate from flowing to the next process. At the same time, the degree of drying can be adjusted by changing the drying air speed, so as to make real-time drying corrections for the webbing substrate subsequently introduced into the device.

[0052] In particular, the second identification process is used to perform a second identification and judgment on the webbing substrate that has been coated with flame retardant after the drying process, so as to determine whether there is a situation where the coating of the dried webbing substrate is broken, resulting in the exposed webbing substrate, thereby making it easier to determine whether to perform the second coating process.

[0053] Furthermore, the second coating device performs a second coating operation on the webbing substrate that has been determined to require coating after a second judgment, thereby compensating for and correcting the exposed parts of the webbing substrate that have become exposed due to drying, covering the exposed areas, and then the second drying device dries the coated webbing substrate to reduce its final exposed area.

[0054] In particular, by using a weighing device to weigh the flame-retardant webbing to be output in real time, the real-time weight per meter of the woven webbing is obtained. When the real-time weight per meter of the webbing exceeds the standard weight per meter of the webbing, it means that while the surface can achieve the required adhesion force under the current weaving pitch parameters, the amount of natural material fibers involved is too large, resulting in an excessively high real-time weight per meter of the webbing. At this time, the real-time weight per meter of the webbing can be adjusted by reducing the amount of natural material fibers involved, so as to reduce the weight of the final product and make it easier to use. Attached Figure Description

[0055] Figure 1 This is a flowchart of the weaving process for the flame-retardant webbing in this embodiment;

[0056] Figure 2 This is a flowchart of each process in the production line for the flame-retardant webbing of this embodiment;

[0057] Figure 3 This is a flowchart of the weaving process in this embodiment;

[0058] Figure 4 This is a logic diagram for determining the adjustment of the weaving pitch of natural material fibers in this embodiment. Detailed Implementation

[0059] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0060] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0061] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0062] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0063] Please see Figure 1 and Figure 2 As shown, where, Figure 1 This is a flowchart of the weaving process for the flame-retardant webbing in this embodiment. Figure 2 This is a flowchart of the production line for the flame-retardant webbing weaving process in this embodiment, including flame-retardant material fiber 101, natural material fiber 102, primary braiding sub-thread 103, secondary braiding sub-thread 104, webbing base 105, flame-retardant dyeing box 1, first identification and judgment device 2, first coating device 3, first drying device 4, second identification and judgment device 5, second coating device 6, and second drying device 7.

[0064] Specifically, this embodiment provides a weaving process for flame-retardant webbing, including:

[0065] Step S1, weaving process: Natural material fibers 102 are woven around the primary weaving sub-thread 103 using preset weaving process parameters to obtain a secondary weaving sub-thread 104 with natural material fibers 102 wrapped on its surface. The secondary weaving sub-thread 104 is then woven to form the required webbing base 105.

[0066] Among them, the preset weaving process parameters include the weaving pitch and the number of natural material fibers 102 involved;

[0067] Step S2, dyeing process: The webbing substrate 105 is introduced into the flame retardant dyeing tank 1, and the flame retardant liquid in the flame retardant dyeing tank 1 is used to dye the webbing substrate 105 as a whole.

[0068] Step S3, the first identification process, the first identification and judgment device 2 performs real-time image acquisition on the webbing substrate 105 that has completed the dyeing process, and calculates the real-time adhesion rate based on the real-time image acquisition results. The real-time adhesion rate of the webbing substrate 105 is judged by the standard adhesion rate to determine whether the weaving pitch of the natural material fiber 102 should be adjusted.

[0069] Step S4, the first coating process, determines whether to perform flame retardant spraying operation on the dyed webbing substrate 105 through the first coating device 3 based on the judgment result of step S3.

[0070] Step S5, drying process, the webbing base 105 is dried by the first drying device 4 at a preset drying wind speed;

[0071] In step S5, it is necessary to ensure that the webbing substrate 105 introduced into the first drying device 4 can be dried normally within the same time interval. Therefore, its drying temperature must always be kept within a relatively stable constant temperature range. Generally speaking, the drying temperature of the room temperature drying oven used for coating drying should not be lower than 100 degrees Celsius. Its maximum temperature should be set according to the actual selection of natural material fiber 102 and flame retardant material fiber 101 selected in the actual production process. However, its maximum temperature should generally not be higher than 150 degrees Celsius. In this embodiment, a constant temperature of 115 degrees Celsius is used as the drying temperature of the first drying device 4 and the second drying device 5.

[0072] Step S6, the second identification process, the second identification and judgment device 5 performs a second real-time image acquisition on the webbing substrate 105 that has completed the drying process, and calculates the real-time bareness rate of the webbing substrate 105 based on the results of the second real-time image acquisition, and judges the real-time bareness rate of the webbing substrate 105 based on the preset bareness rate, so as to determine whether to adjust the drying wind speed of the first drying device 4.

[0073] Step S7, the second coating process, involves using the second coating device 6 to perform a second spraying operation of flame retardant liquid on the webbing substrate 105 that needs to be adjusted after being identified in step S6.

[0074] Step S8, secondary drying process, the webbing base 105 after being coated in step S7 is dried a second time by the second drying device 7. If the webbing base 105 has not been processed in step S7, it will directly proceed to step S9.

[0075] Step S9, Inspection Process: The flame-retardant webbing produced is weighed using a weighing device to obtain the real-time weight per meter of the flame-retardant webbing. Based on the standard weight per meter of the webbing, the real-time weight per meter of the flame-retardant webbing is judged to determine whether the amount of natural material fiber 102 involved should be adjusted.

[0076] Please see Figure 3 As shown, it is a flowchart of the weaving process in this embodiment;

[0077] Specifically, step S1 includes,

[0078] Step S101: Several flame-retardant material fibers 101 are woven into primary braided sub-threads 103 through the first weaving process;

[0079] In step S102, the output end of the first-level braided sub-thread 103, which has been woven in the first braiding process, is fed into the second braiding process in real time, and the natural material fiber 102 is woven around the first-level braided sub-thread 103 with preset braiding process parameters to obtain the second-level braided sub-thread 104 with the natural material fiber 102 wrapped on the surface.

[0080] In step S103, several secondary braiding sub-threads 104 output from the second braiding process are fed into the third braiding process in real time, and the secondary braiding sub-threads 104 are braided into a webbing base 105.

[0081] By progressively dividing the weaving process into a first weaving process, a second weaving process, and a third weaving process, each weaving process can be carried out in an orderly and gradual manner. By adjusting the weaving pitch and the number of natural material fibers 102 in the second weaving process in real time, the natural material fibers 102 can be wound and woven onto the outer surface of each first-level weaving sub-thread 103 according to the real-time state of the flame-retardant webbing. This allows the surface roughness of the resulting second-level weaving sub-thread 104 and the webbing base 105 woven from the second-level weaving sub-thread 104 to be adjusted and corrected in real time according to the real-time state. As a result, the final output webbing base 105 has good tensile strength of flame-retardant material fibers 101 while also having good adhesion of natural material fibers 102 on its surface.

[0082] Please continue reading. Figure 4 As shown, it is the logic diagram for determining the adjustment of the weaving pitch of natural material fibers in this embodiment;

[0083] Specifically, in step S3, a standard color value and a standard color fluctuation difference value for the flame retardant liquid are set, and a judgment range is formed based on the standard color value and the standard color fluctuation difference value.

[0084] In step S3, the real-time image of the webbing substrate 105 acquired by the first identification and determination device 2 is divided into several regions. The color value of each pixel in any region is obtained, and the average value of the color values ​​of each pixel in that region is calculated as the marker color value of that region.

[0085] Based on the judgment range formed by the difference between the standard color value and the standard color fluctuation value, the marked color values ​​of each zone in the real-time image of the webbing substrate 105 are judged and marked respectively.

[0086] If the color value of any partition is within the judgment range, then the partition is marked as the attachment area;

[0087] If the color value of any partition is outside the judgment range, then that partition will not be marked.

[0088] By dividing each pixel in the image acquisition into multiple judgment regions and comparing the marked color value of the pixel in each judgment region with the calculated judgment range, the real-time adhesion degree of the flame retardant liquid at the webbing substrate 105 is visualized to facilitate judgment and comparison, and to facilitate subsequent calculation of the real-time adhesion rate Fs between the flame retardant liquid and the webbing substrate 105.

[0089] In this embodiment, the standard color value of the flame retardant liquid should be selected according to the type of flame retardant liquid actually used or the color of the added dye. For example, when a red dye is used to color the flame retardant liquid to help distinguish it, if the RGB value of the flame retardant liquid is (240, 30, 30), then its color value is calculated as 240+30+30=300. That is, in this embodiment, the value 300 is used as the standard color value of the flame retardant liquid. The standard color fluctuation difference is affected by factors such as ambient light and dyeing impurities. Therefore, it should also be selected and set according to the production scenario in the actual production process. It will not be elaborated here, but generally speaking, the standard color fluctuation difference should not be greater than 30.

[0090] Specifically, in step S3, the total area of ​​the real-time image of the webbing substrate 105 is obtained by the first identification and determination device 2, and the total area of ​​all the partitions with attachment area markings in the real-time image is obtained according to the partition marking results of the real-time image. The real-time attachment rate of the current webbing substrate 105 is calculated based on the total area of ​​the real-time image and the total area of ​​all the partitions with attachment area markings.

[0091] Where Fs = S1 / S, Fs is the real-time attachment rate, S1 is the total area of ​​all regions with attachment area markers in the real-time image, and S is the total area of ​​the real-time image.

[0092] In this embodiment, the image is divided using an equal area division method. The number of image regions divided can directly affect the accuracy of real-time adhesion rate calculation. The accuracy of real-time adhesion rate calculation can be improved by dividing more regions. In actual use, the corresponding division settings should be made in combination with the computing power of the image processing device. Usually, the number of regions divided is not less than 100.

[0093] For example, when the image acquisition area is divided into N image judgment areas, and the acquisition area of ​​each image judgment area is A, then the total area of ​​the real-time image is S = N × A. If there are Nf attachment area markers in the real-time image, then the total area of ​​all attachment area markers in the real-time image is S1 = Nf × A, that is, the real-time attachment rate is Fs = (Nf × A) / (N × A).

[0094] Specifically, in step S3, a standard adhesion rate is also set. When the first identification and judgment device 2 finishes calculating the real-time adhesion rate, it compares the real-time adhesion rate with the standard adhesion rate.

[0095] If the real-time adhesion rate is less than the standard adhesion rate, the weaving pitch in step S1 will be adjusted according to the real-time adhesion rate and the standard adhesion rate.

[0096] If the real-time adhesion rate is greater than or equal to the standard adhesion rate, then the comparison passes without needing to adjust the weaving pitch in step S1.

[0097] By comparing the calculated real-time adhesion rate with the standard adhesion rate, the degree of impregnation of the current webbing substrate 105 is determined. If the real-time adhesion rate is less than the standard adhesion rate, it means that the degree of impregnation of the current webbing substrate 105 does not meet the required impregnation standard, and therefore it needs to be corrected. In other words, the interfacial adhesion between the surface of the webbing substrate 105 and the flame retardant liquid is insufficient. Therefore, it is necessary to reduce the pitch between the natural material fibers 102 wrapped on the surface to increase their coverage of the flame retardant material fibers 101, thereby increasing the adhesion of the subsequent webbing substrate 105 surface.

[0098] Specifically, when the real-time adhesion rate of the webbing substrate 105 is less than the standard adhesion rate, the weaving pitch parameter of the natural material fiber 102 in step S1 will be obtained, and the weaving pitch parameter of the natural material fiber 102 will be corrected according to the real-time adhesion rate and the standard adhesion rate.

[0099] Where Q'=Q×[1+(Fb-Fs) / Fb], Q' is the corrected weaving pitch of the natural material fiber 102, Q is the weaving pitch of the natural material fiber 102 in the current weaving process, Fb is the set standard adhesion rate, and Fs is the real-time adhesion rate.

[0100] In this embodiment, the weaving pitch and standard adhesion rate of the natural material fiber 102 should be selected according to the material of the natural material fiber 102 actually used and the flame retardant effect of the required flame retardant webbing. They should also be set in conjunction with the actual production process. Generally, the standard adhesion rate of the webbing with flame retardant requirements is not less than 0.96.

[0101] We will not go into too much detail here, and it will not affect the actual operation by the implementers.

[0102] Furthermore, when the calculated real-time adhesion rate is less than the standard adhesion rate, the first identification process determines that the current webbing substrate 105 needs to be coated for the first time, and the first coating process corrects the coating of the webbing substrate 105 that needs to be coated after determination. That is, when the first identification process determines that the real-time adhesion rate of the current webbing substrate 105 is less than the standard adhesion rate, it means that the degree of impregnation of the current webbing substrate 105 cannot meet the required flame retardant effect. Therefore, the first coating device is needed to make up for and correct the impregnated webbing substrate 105 to prevent the substandard impregnation of the webbing substrate 105 from flowing to the next process.

[0103] Specifically, in step S6, a current color fluctuation difference value is set to determine the current color value of the webbing substrate 105. The standard color values ​​of the natural material fiber 102 and the flame-retardant material fiber 101 are obtained. Based on the standard color values ​​of the natural material fiber 102 and the flame-retardant material fiber 101, the exposed color range of the natural material fiber 102 and the exposed color range of the flame-retardant material fiber 101 are calculated respectively.

[0104] Wherein, Yb1=Yb-ΔY, Yb2=Yb+ΔY, Ya1=Ya-ΔY, Ya2=Ya+ΔY, Yb is the standard color value of natural material fiber 102, Ya is the standard color value of flame retardant material fiber 101, ΔY is the current color fluctuation difference, Yb1 is the minimum value of the exposed color range of natural material fiber 102, Yb2 is the maximum value of the exposed color range of natural material fiber 102, Ya1 is the minimum value of the exposed color range of flame retardant material fiber 101, and Ya2 is the maximum value of the exposed color range of flame retardant material fiber 101;

[0105] The second identification and judgment device 5 performs secondary real-time image acquisition on the webbing substrate 105, extracts the real-time color value of the secondary real-time image, determines the image area in the secondary real-time image within the exposed color range of the natural material fiber 102 as the first exposed area, and determines the image area in the secondary real-time image within the exposed color range of the flame-retardant material fiber 101 as the second exposed area, and calculates the real-time exposed rate based on the total image area of ​​the acquired secondary real-time images.

[0106] Where Ls=(S1+S2) / Sz, S1 is the first exposed area, S2 is the second exposed area, Sz is the total area of ​​the secondary real-time image, and Ls is the real-time exposed area rate.

[0107] The real-time bare leakage rate is compared with the standard bare leakage rate.

[0108] If the real-time bare leakage rate is greater than the standard bare leakage rate, it is determined that there is a defect in the webbing base 105 at the current position, and the real-time drying air speed in step S5 is adjusted according to the real-time bare leakage rate and the standard bare leakage rate.

[0109] If the real-time bare leakage rate is less than or equal to the standard bare leakage rate, it is determined that there is no defect in the current position of the webbing substrate 105, and there is no need to adjust the drying air speed in step S5.

[0110] In this embodiment, the standard color value Yb of the natural material fiber 102 and the standard color value Ya of the flame-retardant material fiber 101 should both be selected according to the color of the required material itself. For example, if white cotton thread with an RGB value of (250, 200, 200) is used as the natural material fiber 102, and black flame-retardant polyester with an RGB value of (10, 10, 10) is used as the flame-retardant material fiber 101, then the standard color value Yb of the natural material fiber 102 is calculated as 250 + 200 + 200 = 650, and the standard color value Ya of the flame-retardant material fiber 101 is calculated as 10 + 10 + 10 = 30. The value of ΔY for determining the color difference should also be set according to the color of the selected material itself. Due to the color of the material itself, the ΔY for determining the color difference may have a large error, but generally speaking, the ΔY for determining the color difference should not be greater than 50.

[0111] Specifically, when the real-time bare leakage rate of the webbing substrate 105 is greater than the standard bare leakage rate, the drying wind speed parameter of the first drying device 4 in step S5 will be obtained, and the drying wind speed parameter of the first drying device 4 will be corrected according to the real-time bare leakage rate and the standard bare leakage rate.

[0112] Where V'=V×(Lb / Ls), V' is the corrected drying air velocity of the first drying device 4, V is the current drying air velocity of the first drying device 4, Lb is the set standard leakage rate, and Ls is the real-time leakage rate.

[0113] By comparing the calculated real-time leakage rate with the standard leakage rate, the second identification device 5 can determine the coverage of the flame retardant liquid on the current webbing substrate 105. When the real-time leakage rate is greater than the standard leakage rate, it means that the coverage of the flame retardant liquid on the surface of the dried webbing substrate 105 does not meet the required standard, and there is leakage on the surface of the webbing substrate 105. It needs to be coated and corrected. That is, the drying wind speed in the second drying device may be too high, causing the flame retardant liquid on the surface of the webbing substrate 105 to dry too quickly, resulting in breakage and leakage. Therefore, the real-time drying wind speed in the first drying device 4 needs to be reduced to make the drying speed more uniform.

[0114] However, the drying wind speed in the first drying device 4 should be set to a minimum wind speed value. When the real-time drying wind speed of the first drying device 4 is lower than the minimum wind speed value, an alarm will be triggered to avoid the situation where the flame retardant liquid at the webbing base 105 fails to dry properly due to the low wind speed. The minimum wind speed value should also be set in conjunction with the actual production process. Under normal circumstances, the minimum drying wind speed value should not be lower than 1 m / s.

[0115] Specifically, in step S9, the real-time weight of the webbing detected by the weighing device is determined according to the standard webbing weight per meter. If the real-time weight of the webbing detected by the weighing device is greater than the standard webbing weight per meter, it is determined that the current flame-retardant webbing has a defect in its own weight, and the participation quantity of natural material fiber 102 in step S1 is adjusted according to the real-time webbing weight per meter and the standard webbing weight per meter.

[0116] Where N' = NN × (Gs - Gb) / Gb, N' is the number of natural material fibers 102 involved after correction, N is the preset number of natural material fibers 102 involved, Gb is the set standard webbing weight per meter, Gs is the real-time webbing weight per meter, and when N × (Gs - Gb) / Gb is less than 1, it is automatically corrected to 1;

[0117] If the real-time weight per meter of the webbing is less than or equal to the weight per meter of the standard webbing, it is determined that the weight of the current flame-retardant webbing is normal, and the output end of the current flame-retardant webbing is put into the winding and sealing device for sealing and output.

[0118] Where N' = NN × (Gs - Gb) / Gb, N' is the number of natural material fibers 102 involved after correction, N is the preset number of natural material fibers 102 involved, Gb is the set standard webbing weight per meter, Gs is the real-time webbing weight per meter, and when N × (Gs - Gb) / Gb is less than 1, it is automatically corrected to 1.

[0119] The flame-retardant webbing to be output is weighed in real time by a weighing device to obtain the real-time weight per meter of the woven webbing. When the real-time weight per meter of the webbing exceeds the standard weight per meter of the webbing, it means that while the surface can achieve the required adhesion force under the current weaving pitch parameters, the amount of natural material fibers 102 involved is too large, resulting in an excessively high real-time weight per meter of the webbing. At this time, the real-time weight per meter of the webbing can be adjusted by reducing the amount of natural material fibers 102 involved, so as to reduce the weight of the final product and make it easier to use.

[0120] Meanwhile, to avoid the number of natural material fibers 102 involved being too low, a minimum number of involvement is preset. In this embodiment, the minimum number of involvement is set to 1. An alarm is triggered when the number of natural material fibers 102 involved is less than or equal to 1.

[0121] Furthermore, the standard webbing weight per meter in this embodiment should be preset according to the application scenario of the required flame-retardant webbing, and should also be selected in conjunction with the weighing method of the actual weighing equipment. Since the flame-retardant webbing in this embodiment is produced in real time, the weighing equipment needs to weigh and calculate a portion of it without cutting the real-time webbing, which will result in a slight error. In actual production, it is also necessary to determine the weight based on the size parameters of the real-time webbing. The unit for calculating the standard webbing weight per meter is grams per meter. Other methods will not be described in detail here, and will not affect the actual operation by those skilled in the art.

[0122] In another aspect, the present invention provides a flame-retardant webbing produced based on any one of the above-mentioned flame-retardant webbing weaving processes.

[0123] It includes flame-retardant material fibers 101, natural material fibers 102, and a flame-retardant layer formed by impregnation and coating with a flame-retardant liquid.

[0124] Among them, flame retardant material fiber 101 includes one or more of flame retardant polyester fiber, flame retardant nylon fiber and halogen-free flame retardant polyester fiber;

[0125] Natural material fiber 102 includes one or more of cotton fiber, hemp fiber and silk fiber;

[0126] The flame retardant liquid contains one or more of the following: halogenated flame retardants, phosphorus-based flame retardants, and inorganic flame retardants.

[0127] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0128] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A weaving process for flame-retardant webbing, characterized in that, include, Step S1, weaving process: using preset weaving process parameters, natural material fibers are woven around the primary weaving thread to obtain a secondary weaving thread with the natural material fibers wrapped on its surface. The secondary weaving thread is then woven to form the desired webbing base. The preset weaving process parameters include the weaving pitch and number of natural material fibers involved, and several flame-retardant material fibers are woven into a primary braided sub-thread. Step S2, dyeing process: The webbing substrate is introduced into a flame-retardant dyeing tank, and the flame-retardant liquid in the flame-retardant dyeing tank is used to dye the entire webbing substrate. Step S3, the first identification process, involves real-time image acquisition of the webbing substrate after the dyeing process is completed by the first identification and determination device, and real-time adhesion rate is calculated based on the real-time image acquisition results. The real-time adhesion rate of the webbing substrate is determined by the standard adhesion rate to determine whether the weaving pitch of the natural material fiber should be adjusted. Step S4, the first coating process, determines whether to perform flame retardant spraying operation on the dyed webbing substrate through the first coating device based on the judgment result of step S3. Step S5, drying process, the webbing base is dried by the first drying device at a preset drying wind speed; Step S6, the second identification process, the second identification and determination device performs a second real-time image acquisition on the webbing substrate that has completed the drying process, and calculates the real-time bareness rate of the webbing substrate based on the results of the second real-time image acquisition. The real-time bareness rate of the webbing substrate is determined based on the preset bareness rate to determine whether the drying wind speed of the first drying device should be adjusted. Step S7, the second coating process, involves using a second coating device to perform a second spraying operation of flame retardant liquid on the webbing substrate that needs adjustment after being identified in step S6. Step S8, secondary drying process, the webbing substrate after being coated in step S7 is dried a second time using a second drying device. If the webbing substrate has not been processed in step S7, it proceeds directly to step S9. In step S9, the inspection process, the flame-retardant webbing that has been produced is weighed using a weighing device to obtain the real-time weight per meter of the flame-retardant webbing. Based on the standard weight per meter of the webbing, the real-time weight per meter of the flame-retardant webbing is determined to decide whether the amount of natural material fiber involved should be adjusted.

2. The weaving process of the flame-retardant webbing according to claim 1, characterized in that, In step S1, the following are included: Step S101: Several flame-retardant material fibers are woven into primary braided sub-threads through the first weaving process; Step S102: The output end of the first-level braided sub-thread completed in the first braiding process is fed into the second braiding process in real time, and the natural material fibers are braided around the first-level braided sub-thread using preset braiding process parameters to obtain a second-level braided sub-thread with natural material fibers wrapped around its surface. Step S103: The secondary braiding sub-threads output from the second braiding process are fed into the third braiding process in real time to braid the secondary braiding sub-threads into the webbing base.

3. The weaving process of a flame-retardant webbing according to claim 1, characterized in that, In step S3, a standard color value and a standard color fluctuation difference value for the flame retardant liquid are set, and a judgment range is formed based on the standard color value and the standard color fluctuation difference value. In step S3, the real-time image of the webbing substrate acquired by the first identification and determination device is divided into several regions. The color value of each pixel in any region is obtained, and the average value of the color values ​​of each pixel in that region is calculated as the marker color value of that region. The marking color values ​​of each zone in the real-time image of the webbing substrate are marked according to the judgment range formed by the difference between the standard color value and the standard color fluctuation value. If the color value of any partition is within the judgment range, then the partition is marked as the attachment area; If the color value of any partition is outside the judgment range, then that partition will not be marked.

4. The weaving process of the flame-retardant webbing according to claim 3, characterized in that, In step S3, the total area of ​​the real-time image of the webbing substrate is obtained by the first identification and determination device, and the total area of ​​all partitions with attachment area markings in the real-time image is obtained according to the partition marking results of the real-time image. The real-time attachment rate of the current webbing substrate is calculated based on the total area of ​​the real-time image and the total area of ​​all partitions with attachment area markings. Where Fs = S1 / S, Fs is the real-time attachment rate, S1 is the total area of ​​all regions with attachment area markers in the real-time image, and S is the total area of ​​the real-time image.

5. The weaving process of the flame-retardant webbing according to claim 4, characterized in that, In step S3, a standard adhesion rate is also set. After the first identification and determination device finishes calculating the real-time adhesion rate, the real-time adhesion rate is compared with the standard adhesion rate. If the real-time adhesion rate is less than the standard adhesion rate, the weaving pitch in step S1 will be adjusted according to the real-time adhesion rate and the standard adhesion rate.

6. The weaving process of the flame-retardant webbing according to claim 5, characterized in that, When the real-time adhesion rate of the webbing substrate is less than the standard adhesion rate, the weaving pitch parameter of the natural material fiber in step S1 will be obtained, and the weaving pitch parameter of the natural material fiber will be corrected according to the real-time adhesion rate and the standard adhesion rate. Where Q' = Q × [1 + (Fb - Fs) / Fb], Q' is the corrected weaving pitch of the natural material fiber, Q is the weaving pitch of the natural material fiber in the current weaving process, Fb is the set standard adhesion rate, and Fs is the real-time adhesion rate.

7. The weaving process of the flame-retardant webbing according to claim 1, characterized in that, In step S6, a current color fluctuation difference value is set to determine the current color value of the webbing substrate. The standard color values ​​of the natural material fiber and the flame-retardant material fiber are obtained. Based on the standard color values ​​of the natural material fiber and the flame-retardant material fiber, the exposed color range of the natural material fiber and the exposed color range of the flame-retardant material fiber are calculated respectively. Where Yb1=Yb-ΔY, Yb2=Yb+ΔY, Ya1=Ya-ΔY, Ya2=Ya+ΔY, Yb is the standard color value of natural material fiber, Ya is the standard color value of flame retardant material fiber, ΔY is the current color fluctuation difference, Yb1 is the minimum value of the exposed color range of natural material fiber, Yb2 is the maximum value of the exposed color range of natural material fiber, Ya1 is the minimum value of the exposed color range of flame retardant material fiber, and Ya2 is the maximum value of the exposed color range of flame retardant material fiber; The second identification and determination device performs secondary real-time image acquisition on the webbing substrate, extracts the real-time color value of the secondary real-time image, determines the image area of ​​the real-time color value in the secondary real-time image within the exposed color range of natural material fiber as the first exposed area, and determines the image area of ​​the real-time color value within the exposed color range of flame retardant material fiber as the second exposed area, and calculates the real-time exposed rate based on the total image area of ​​the acquired secondary real-time image. Where Ls = (S1 + S2) / Sz, S1 is the first exposed area, S2 is the second exposed area, Sz is the total area of ​​the secondary real-time image, and Ls is the real-time exposed area rate. The real-time bare leakage rate is compared with the standard bare leakage rate. If the real-time leakage rate is greater than the standard leakage rate, it is determined that there is a defect in the webbing substrate at the current position, and the real-time drying air speed in step S5 is adjusted according to the real-time leakage rate and the standard leakage rate.

8. The weaving process of the flame-retardant webbing according to claim 7, characterized in that, When the real-time bare leakage rate of the webbing substrate is greater than the standard bare leakage rate, the drying wind speed parameter of the first drying device in step S5 will be obtained, and the drying wind speed parameter of the first drying device will be corrected according to the real-time bare leakage rate and the standard bare leakage rate. Where V' = V × (Lb / Ls), V' is the corrected drying air velocity of the first drying device, V is the current drying air velocity of the first drying device, Lb is the set standard leakage rate, and Ls is the real-time leakage rate.

9. The weaving process of the flame-retardant webbing according to claim 1, characterized in that, In step S9, the real-time weight of the webbing detected by the weighing device is determined in real time according to the set standard weight per meter of webbing. If the real-time weight of the webbing detected by the weighing device is greater than the standard weight per meter of webbing, it is determined that the current weight of the flame-retardant webbing itself is defective, and the amount of natural material fiber involved in step S1 is adjusted according to the real-time weight per meter of webbing and the standard weight per meter of webbing. Where N'=NN×(Gs-Gb) / Gb, N' is the corrected number of natural material fibers involved, N is the preset number of natural material fibers involved, Gb is the set standard webbing weight per meter, Gs is the real-time webbing weight per meter, and when N×(Gs-Gb) / Gb is less than 1, it is automatically corrected to 1. If the real-time weight per meter of the webbing is less than or equal to the weight per meter of the standard webbing, it is determined that the weight of the current flame-retardant webbing is normal, and the output end of the current flame-retardant webbing is passed into the winding and sealing device for sealing and output.

10. A flame-retardant webbing produced using the weaving process described in any one of claims 1-9, characterized in that, The flame-retardant webbing includes flame-retardant material fibers, natural material fibers, and a flame-retardant layer formed by impregnation and coating with a flame-retardant liquid. The flame-retardant material fiber includes one or more of flame-retardant polyester fiber, flame-retardant nylon fiber, and halogen-free flame-retardant polyester fiber. The natural material fibers include one or more of cotton fibers, hemp fibers, and silk fibers; The flame retardant liquid composition includes one or more of halogenated flame retardants, phosphorus-based flame retardants, and inorganic flame retardants.

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