Fully formed rigid-flexible coupling stab-resistant fabric and method of making same

Abstract

The application relates to a full-molding rigid-flexible coupling anti-puncture fabric and a preparation method thereof, and relates to the field of protective textile materials. The application provides a full-molding rigid-flexible coupling anti-puncture fabric and a preparation method thereof, wherein linear protective blocks are integrated in a fabric interlayer, and the linear protective blocks are filled with compact and thick fabric at non-laid positions, excellent anti-puncture performance and durability of the fabric are achieved, good flexibility is maintained, a resin and fabric compounding process is effectively reduced, and processing clothing efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of protective textile materials technology, and in particular to a fully formed rigid-flexible coupled stab-resistant fabric and its preparation method. Background Technology

[0002] In recent years, personal protective equipment (PPE) used to defend against stab wounds and protect the lives of military personnel, police officers, and security personnel has received widespread attention from the market and researchers. As awareness of the necessity of safety protection grows, the importance of developing related products has become increasingly apparent. Currently, soft stab-resistant vests have significant advantages in the market, using soft and comfortable fabrics combined with resin coatings, STF impregnation, and other methods to create composite materials with excellent protective performance. However, these materials often struggle to simultaneously provide both protection and flexibility, further limiting their practical applications.

[0003] In related technologies, many researchers have proposed improving the flexibility and breathability of textiles by covering them with discontinuous coatings. For example, patent CN105403106B discloses a scale-like anti-stab chip and an anti-stab device made therefrom. The anti-stab device made using orderly arranged scale-like anti-stab chips overcomes the problems of existing protective equipment being generally heavy, having poor breathability, complex protective layer structures, cumbersome manufacturing processes, and high costs. Patent CN105526830A discloses a biomimetic anti-stab chip, which uses multiple semi-ellipsoidal groups arranged sequentially along a preset direction to obtain an anti-stab device with excellent protective performance.

[0004] While the related technologies mention that the orderly arrangement of protective blocks imparts good cut resistance, puncture resistance, and abrasion resistance to the material, and the gaps between adjacent protective blocks ensure good air permeability and mechanical flexibility of the textile substrate, these methods inevitably require the integration of the protective blocks and textiles through resin thermosetting and compression bonding. This limits the use of some heat-sensitive polymer fabrics with poor thermal stability, the entire weaving cycle is very long and cumbersome, and obvious protective weaknesses may emerge. Furthermore, for fabrics with low surface energy, the interfacial adhesion strength is another aspect that needs to be considered. Summary of the Invention

[0005] The purpose of this application is to provide a fully formed rigid-flexible coupled stab-resistant fabric and its preparation method to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0007] In a first aspect, this application provides a method for preparing a fully formed rigid-flexible coupled stab-resistant fabric, wherein the fully formed rigid-flexible coupled stab-resistant fabric is composed of a plurality of minimum cycle organizational units, and the method for preparing the minimum cycle organizational units includes:

[0008] S1. Weave the fabric yarns back and forth, connecting them together between the needle bed and filling the interior;

[0009] S2. The fabric yarns are independently and fully looped on the front and back needle beds without being connected, forming a hollow interlayer that fits the linear protective block. The fabric yarns without the interlayer are knitted in cotton and wool on the front and back needle beds and connected multiple times.

[0010] S3. Linear protective blocks are inserted into the hollow interlayer, and connecting yarns that serve as connectors are used in the front and rear needle beds.

[0011] S4. After the linear protective block is inserted into the hollow interlayer, the knitting needles at the hollow interlayer do not work and the yarn tip does not touch the linear protective block, and then knit multiple rows, and finally start the stitches to seal.

[0012] In one possible implementation, the linear protective block is composed of thermosetting resin blocks and connecting wires, with several of the thermosetting resin blocks connected together by the connecting wires.

[0013] In one possible implementation, the linear protective block is made by curing thermosetting resin on a protective block mold, the protective block mold being provided with a groove corresponding to the shape of the thermosetting resin block and microgrooves corresponding to the shape of the connecting wire.

[0014] In one possible implementation, the method for preparing the linear protective block includes:

[0015] Based on the desired shape of the linear protective block, the required protective block mold is made, and the thermosetting resin and its corresponding curing agent are mixed according to the required proportions to obtain a thermosetting resin mixture.

[0016] In response to placing the connecting wire in the microgroove of the protective block mold, the thermosetting resin mixture is poured into the mold groove, and the linear protective block is obtained after curing.

[0017] In one possible implementation, in step S2:

[0018] The process at the hollow interlayer is different from that at the non-interlayer section. The non-interlayer section consists of multiple rows forming a single coil, which differs from the fully coiled coil at the hollow interlayer section.

[0019] In one possible implementation, the coil difference between the hollow interlayer and the non-interlayer portion allows the coil in the hollow interlayer to have a deformation effect, which is used to ensure that the linear protective block in the hollow interlayer can sink into the needle bed gap even without weaving.

[0020] In one possible implementation, the method employs a fully knitted fabric process, wherein the yarn guide of the flat knitting machine used in the method does not follow the movement of the machine head and can move independently on the track as needed.

[0021] In one possible implementation, the thermosetting resin includes at least one of phenolic resin, polyester resin, epoxy resin, vinyl ester, bismaleimide, and thermosetting polyimide.

[0022] In one possible implementation, the connecting wire includes at least one of carbon fiber, high-strength polyester, aramid, modified ultra-high molecular weight polyethylene, and aramid / polyethylene composite yarn.

[0023] Secondly, this application provides a fully formed rigid-flexible coupled stab-resistant fabric, which is prepared by the preparation method of the fully formed rigid-flexible coupled stab-resistant fabric as described above.

[0024] The beneficial effects of the technical solution provided in this application include at least the following:

[0025] This application provides a fully formed rigid-flexible coupled stab-resistant fabric and its preparation method. The linear protective blocks are integrated into the fabric interlayer, and the areas not covered by the linear protective blocks are filled with dense and thick fabric. This achieves excellent stab resistance and durability of the fabric, while maintaining good flexibility. It effectively reduces the resin-fabric composite process and improves the efficiency of garment processing. Attached Figure Description

[0026] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings:

[0027] Figure 1 This invention provides a schematic diagram illustrating the independent movement of the yarn guide and the knitting head of an ADF series stoll flat knitting machine according to an exemplary embodiment of this application.

[0028] Figure 2 This invention provides a schematic diagram of the structure of an ADF series stoll flat knitting machine in a knitting state, according to an exemplary embodiment of the present application.

[0029] Figure 3 A process flow diagram of a method for preparing a fully formed rigid-flexible coupled stab-resistant fabric provided in an exemplary embodiment of this application is shown.

[0030] Figure 4 This invention provides a schematic diagram of the structure of a protective block mold according to an exemplary embodiment of the present application.

[0031] Figure 5The following diagram illustrates the dynamic stab resistance test results of a fabric provided in an exemplary embodiment of this application: (a) is a test result diagram of the hollow interlayer of the fully formed rigid-flexible coupling stab resistance fabric, and (b) is a test result diagram of the non-interlayer portion of the fully formed rigid-flexible coupling stab resistance fabric. Detailed Implementation

[0032] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0033] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0034] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0035] Figure 1 This invention provides a schematic diagram illustrating the independent movement of the yarn guide and the knitting head of an ADF series stoll flat knitting machine according to an exemplary embodiment. Figure 2 A schematic diagram of the structure of the ADF series stoll flat knitting machine in the knitting state, provided in an exemplary embodiment of this application, is shown. Figure 1 , Figure 2 The diagram shows a hollow interlayer 1, a non-interlayer section 2, a linear protective block 3, and a yarn guide 4.

[0036] In this embodiment, the aforementioned ADF series stollen flat knitting machine possesses a powerful yarn guiding system. The knitting head and yarn guide 4 are separated and operate independently, allowing the machine to stop and run on the track according to process requirements. Figure 1 As shown, this ensures that the yarn guide 4 of the machine will not collide with the protruding part of the linear protective block after it has been inserted, thus preventing damage, as the machine head moves back and forth. Furthermore, as... Figure 1 and Figure 2As shown, the ADF series stoll flat knitting machine features a top-feed design, eliminating most of the feeding system and facilitating the feeding of irregular linear guard blocks 3 at designated positions and times.

[0037] Figure 3 A process flow diagram of a method for preparing a fully formed rigid-flexible coupled stab-resistant fabric according to an exemplary embodiment of this application is shown. The method uses the aforementioned ADF series Stoll flat knitting machine for weaving. The main skeleton structure of the fully formed rigid-flexible coupled stab-resistant fabric is a modified cotton-wool structure. The fully formed rigid-flexible coupled stab-resistant fabric is composed of several minimum cycle weave units. The method for preparing the minimum cycle weave units includes:

[0038] S1. Before the linear protective block 3 is woven in, the fabric yarn is woven back and forth, connected to each other between the needle bed and filled inside it;

[0039] S2. The fabric yarns are independently knitted in full loops on the front and back needle beds without being connected, forming a hollow interlayer 1 that fits the linear protective block. The fabric yarns in the non-interlayer part 2 (i.e., the part other than the hollow interlayer 1) are knitted in cotton wool on the front and back needle beds and connected multiple times, making the fabric very tight and thick even in the area without the linear protective block 3, providing effective puncture protection and also serving to fix the linear protective block 3. The process of the hollow interlayer 1 is different from that of the non-interlayer part 2. The non-interlayer part 2 has multiple rows forming a single loop, which is different from the loops formed in the hollow interlayer 1. The difference in loops between the hollow interlayer 1 and the non-interlayer part 2 gives the loops in the hollow interlayer 1 a deformable effect, which is used to ensure that the linear protective block 3 in the hollow interlayer 1 can sink into the gap between the needle beds even when not knitted.

[0040] S3, Incorporate the linear protective block 3 into the process organization Figure 3 The fifth row is inserted into the hollow interlayer 1, and the connecting yarn - aramid - which plays a connecting role participates in the front and back needle bed knitting to reinforce and bind the linear protective block 3;

[0041] S4. After the linear protective block 3 is inserted into the hollow interlayer 1, the knitting needles in the hollow interlayer 1 do not work, and the yarn tip does not touch the linear protective block 3. Multiple rows are knitted, and the loops without the interlayer 2 are pulled down by the machine's traction mechanism, along with the connecting yarn—aramid—that participates in the knitting. Simultaneously, with the fabric yarn hanging on the knitting needles, the highly deformable loops in the hollow interlayer 1 also deform under the machine's tension. The combined effect causes the linear protective block 3 to sink into the needle bed gap. With the help of a highly efficient sinker, the machine can then proceed normally according to the process. Figure 3 Start the knitting process to seal the opening.

[0042] It is worth mentioning that by repeating the weaving of the above minimum cycle unit several times, a fully formed rigid-flexible coupled stab-resistant fabric can be obtained.

[0043] In this embodiment, the linear protective block 3 is composed of thermosetting resin blocks and connecting wires, and several thermosetting resin blocks are connected by connecting wires.

[0044] Optionally, the thermosetting resin includes at least one of the following: phenolic resin, polyester resin, epoxy resin, vinyl ester, bismaleimide, and thermosetting polyimide.

[0045] Optionally, the connecting wire includes at least one of the high-performance fibers that are easily bonded to resin, such as carbon fiber, high-strength polyester, aramid, modified ultra-high molecular weight polyethylene, and aramid / polyethylene composite yarn.

[0046] High-strength polyester, also known as high-strength polyester or high-intensity polyester, is a polyester fiber that has undergone special processing. It has higher strength and better physical properties than ordinary polyester fiber. During the production process, special stretching and heat setting techniques are used to make the molecular arrangement inside the fiber more compact and orderly, thereby obtaining higher strength, toughness and abrasion resistance.

[0047] Modified ultra-high molecular weight polyethylene (UHMWPE) is a special material that has been treated by chemical or physical methods. UHMWPE itself has very high abrasion resistance, impact resistance, and self-lubricating properties, and is often used to manufacture abrasion-resistant parts, bulletproof vests, ropes, and other products. However, in order to further improve its performance, such as improving its processability, enhancing its mechanical properties, or endowing it with specific functionalities, it needs to be modified.

[0048] Aramid / polyethylene composite yarn is a high-performance composite material that combines the advantages of aramid and polyethylene fibers. This type of composite yarn is typically prepared by mixing the two fibers in a specific ratio and then spinning them, or by combining them through other processes.

[0049] Specifically, the linear protective block 3 is made by curing thermosetting resin on a protective block mold. The protective block mold is provided with a mold groove corresponding to the shape of the thermosetting resin block and a micro groove corresponding to the shape of the connecting wire.

[0050] Furthermore, the preparation method of the above-mentioned linear protective block 3 includes:

[0051] Based on the shape of the required linear protective block 3, the required protective block mold is made, and the thermosetting resin and its corresponding curing agent are mixed according to the requirements to obtain a thermosetting resin mixture.

[0052] In response to placing the connecting wire in the microgroove of the protective block mold, a thermosetting resin mixture is poured into the mold groove, and after curing, a linear protective block 3 is obtained.

[0053] It should be noted that this application does not limit the preparation method of the above-mentioned protective block mold. The required mold can be prepared in other ways, such as laser engraving, 3D printing, etc.

[0054] In the first example, acrylic sheets were selected to prepare the protective block mold, and the shape of the protective block mold was constructed by laser engraving. Figure 4 This illustration shows a schematic diagram of the protective block mold provided in an exemplary embodiment of this application. According to the software design, a 10mm × 10mm square and a 1.5mm × 5mm rectangular array (second layer template) are engraved on a 1mm thick template. A 10mm × 10mm square array (first layer template and third layer template) is engraved on two other 1mm thick templates, without any rectangular channels connecting them. Then, according to… Figure 4 As shown, the components are stacked sequentially on a flat plate to form the required protective block mold. Further, E51 epoxy resin and low-molecular-weight 650 polyamide resin curing agent are selected in a 1:1 mass ratio and mixed thoroughly. Before pouring into the protective block mold, 400D aramid fiber is placed as a connecting wire in the rectangular microgroove array of the second layer template to fix the mold. The premixed material is then poured in and cured in an 80℃ oven for 2 hours to obtain a linear protective block.

[0055] In the second example, unlike the first example, the linear protective block is a circular protective block with a diameter of 10mm, so the mold groove of the protective block mold needs to be changed accordingly. In this example, Q301 epoxy resin AB glue is used with a mass ratio of 3:1, mixed and stirred evenly, and 400D carbon fiber is used as the connecting wire and placed in the rectangular microgroove array of the second layer template to prepare the linear protective block.

[0056] Performance testing:

[0057] Next, dynamic stab resistance tests were conducted on the fully formed rigid-flexible coupling stab-resistant fabric prepared with 150D aramid connecting yarn, AB two-component epoxy resin mixed in a 2:1 ratio and cured at room temperature to prepare linear protective blocks, and 400D ultra-high molecular weight polyethylene fabric yarn for the main fabric structure. The test was conducted according to the standard GA68—2019 Police Stab-Resistant Clothing.

[0058] Figure 5The illustration shows the dynamic stab resistance test results of a fabric provided in an exemplary embodiment of this application; (a) is the test result at the hollow layer of the fully formed rigid-flexible coupled stab resistance fabric, and (b) is the test result at the unlayered portion of the fully formed rigid-flexible coupled stab resistance fabric. The fully formed rigid-flexible coupled stab resistance fabric was not punctured by a standard Class A knife D1. Multiple tests were conducted on the fabric, including at the hollow layer of the linear protective block or at the unlayered portion of the linear protective block. At a test energy of 24J, the hollow layer of the fully formed rigid-flexible coupled stab resistance fabric was not punctured, meeting the stab resistance police standard. At a test energy of 18J, the unlayered portion of the fully formed rigid-flexible coupled stab resistance fabric was not punctured, demonstrating good stab resistance.

[0059] In summary, this application provides a fully formed rigid-flexible coupled stab-resistant fabric and its preparation method, which integrates linear protective blocks into the fabric interlayer, and fills the areas not covered by the linear protective blocks with a dense and thick fabric, achieving excellent stab resistance and durability of the fabric, while maintaining good flexibility, effectively reducing the resin-fabric composite process, and improving the efficiency of garment processing.

[0060] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A method for preparing a fully formed rigid-flexible coupled stab-resistant fabric, characterized in that, The method employs a fully formed knitting process, and the yarn guide of the flat knitting machine used in the method does not follow the movement of the machine head, but can move independently on the track as needed. The fully formed rigid-flexible coupled stab-resistant fabric is composed of several minimum circulation units, and the preparation method of the minimum circulation units includes: S1. Weave the fabric yarns back and forth, connecting them together between the needle bed and filling the interior; S2. The fabric yarns are independently and fully looped on the front and back needle beds without being connected, forming a hollow interlayer that fits the linear protective block. The fabric yarns without the interlayer are knitted in cotton and wool on the front and back needle beds and connected multiple times. The process at the hollow interlayer is different from the process at the non-interlayer section. The non-interlayer section has multiple rows forming a single coil, which is different from the fully coiled coil at the hollow interlayer section. The difference between the coils in the hollow interlayer and the coils in the non-interlayer section allows the coils in the hollow interlayer to have a deformation effect, which is used to ensure that the linear protective block in the hollow interlayer can sink into the needle bed gap even without weaving. S3. Linear protective blocks are inserted into the hollow interlayer, and connecting yarns that serve as connectors are used in the front and rear needle beds. S4. After the linear protective block is inserted into the hollow interlayer, the knitting needles at the hollow interlayer do not work and the yarn tip does not touch the linear protective block, and then knit multiple rows, and finally start the stitches to seal it. The linear protective block is composed of thermosetting resin blocks and connecting wires, and several thermosetting resin blocks are connected by the connecting wires.

2. The method for preparing the fully formed rigid-flexible coupled stab-resistant fabric according to claim 1, characterized in that, The linear protective block is made by curing thermosetting resin on a protective block mold. The protective block mold is provided with a mold groove corresponding to the shape of the thermosetting resin block and a microgroove corresponding to the shape of the connecting wire.

3. The method for preparing the fully formed rigid-flexible coupled stab-resistant fabric according to claim 2, characterized in that, The method for preparing the linear protective block includes: Based on the desired shape of the linear protective block, the required protective block mold is made, and the thermosetting resin and its corresponding curing agent are mixed according to the required proportions to obtain a thermosetting resin mixture. In response to placing the connecting wire in the microgroove of the protective block mold, the thermosetting resin mixture is poured into the mold groove, and the linear protective block is obtained after curing.

4. The method for preparing the fully formed rigid-flexible coupled stab-resistant fabric according to claim 2, characterized in that, The thermosetting resin includes at least one of phenolic resin, polyester resin, epoxy resin, vinyl ester, bismaleimide, and thermosetting polyimide.

5. The method for preparing the fully formed rigid-flexible coupled stab-resistant fabric according to claim 2, characterized in that, The connecting wire includes at least one of the following: carbon fiber, high-strength polyester, aramid, modified ultra-high molecular weight polyethylene, and aramid / polyethylene composite yarn.

6. A fully formed rigid-flexible coupled stab-resistant fabric, characterized in that, The fabric is prepared by the method for preparing the fully formed rigid-flexible coupled stab-resistant fabric according to any one of claims 1 to 5.

Images