Nodular arcuate spacer fabric and method of making same

Abstract

The application relates to a segmented arc-shaped spacer fabric and a preparation method thereof, and relates to the field of flat knitting. The segmented arc-shaped spacer fabric provided by the application has an arc-shaped surface and multiple segments, the arc-shaped surface can be conveniently attached to a cylindrical surface, the segmented structure facilitates the bending of the fabric to keep the shape consistent with the protected part, and the spacer layer can play a protective role when the fabric is impacted by external force. In addition, the computerized flat knitting machine is used for one-time knitting forming, the production process is reduced, and the performance loss of the spacer fabric caused by mold pressing and cutting is avoided.

Description

Technical Field

[0001] This application relates to the field of horizontal knitting technology, and in particular to a segmented arc-shaped spacer fabric and its preparation method. Background Technology

[0002] Knitted spacer fabrics are textiles with a certain thickness, mainly woven on flat knitting machines, double-sided weft knitting machines, and double-needle bed warp knitting machines. Knitted spacer fabrics have a wide range of applications. Utilizing the elasticity of the fabric itself, they can be used to make mattresses, cushions, insoles, and protective gear. Utilizing the porous structure of the fabric, they can be used to make sound insulation and heat insulation materials. When combined with resin, they can be used to make hollow composite boards. They can also be used to make pressure sensors, triboelectric generators, and other similar products.

[0003] When knitted spacer fabrics are used as pipe elbow guards or knee and elbow protectors, they need to fit snugly against the protected object. In existing technologies, spacer fabrics woven on flat knitting machines are mainly flat structures, requiring molding or cutting and sewing to create a three-dimensional structure. However, cutting easily causes yarn breakage, and molding easily puts stress on the spacer yarns, thus compromising the performance of the spacer fabric to some extent. Furthermore, the increased production steps reduce production efficiency. Therefore, it is necessary to develop a segmented, arc-shaped spacer fabric that is knitted in one step on a computerized flat knitting machine, eliminating the need for sewing. Summary of the Invention

[0004] The purpose of this application is to provide a segmented arc-shaped spacer fabric and a method for preparing the same, so as to solve the problems existing in the prior art.

[0005] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0006] In a first aspect, this application provides a segmented arc-shaped spacer fabric, including an outer curved surface, an inner curved surface, and a spacer layer for supporting the outer curved surface and the inner curved surface;

[0007] The segmented arc-shaped spacer fabric is segmented longitudinally, and multiple segments can move between each other; the segmented arc-shaped spacer fabric is arc-shaped transversely and is used to fit the protected part.

[0008] In one possible implementation, the segmented arc-shaped spacer fabric includes a support area, a hollow area, and a sewing area; the support area is woven with non-elastic yarn to form the outer curved surface, with elastic yarn to form the inner curved surface, and with high-modulus monofilament to form the spacer layer; the hollow area is woven with non-elastic yarn to form the outer curved surface, with elastic yarn to form the inner curved surface, and without the spacer layer; the sewing area is woven with non-elastic yarn and elastic yarn alternately to form the outer curved surface and the inner curved surface.

[0009] In one possible implementation, the outer and inner curved surfaces of the support area and the hollow area are organized in a single-sided circular pattern.

[0010] In one possible implementation, the spacer layer of the support region employs a double-sided loop structure.

[0011] In one possible implementation, the suture area employs double-sided circular tissue.

[0012] In one possible implementation, each of the support regions constitutes a segment, and multiple segments are connected by the hollow region and the suture region.

[0013] In one possible implementation, the outer curved surface is woven from 50-600D polyester or nylon yarn; the inner curved surface is woven from 50-600D polyester and spandex covered yarn, or nylon and spandex covered yarn; and the spacer layer is woven from polyester monofilaments with a diameter of 0.3-2mm.

[0014] In one possible implementation, the central angle of the arcuate spacer fabric ranges from 30 to 180°, and the thickness of the spacer layer ranges from 5 to 25 mm.

[0015] Secondly, this application provides a method for preparing a segmented arc-shaped spacer fabric, the method being applicable to the segmented arc-shaped spacer fabric described above, the method employing a double-needle bed computerized flat knitting machine with an electronic needle selection device for knitting, the method comprising:

[0016] S1. Double-sided loop structure is knitted on all needles using non-elastic yarn and elastic yarn to form a full row of stitched areas;

[0017] S2. On the middle needle of the front needle bed, a single-sided loop structure is knitted with non-elastic yarn to form the outer curved surface of the hollow area; on the middle needle of the back needle bed, a single-sided loop structure is knitted with elastic yarn to form the inner curved surface of the hollow area; on the left and right edge needles of the front and back needle beds, a double-sided loop structure is knitted with non-elastic yarn and elastic yarn to form the left and right seam areas.

[0018] S3. On the middle needle of the front needle bed, a single-sided loop structure is knitted with non-elastic yarn to form the outer curved surface of the support area; on the middle needle of the back needle bed, a single-sided loop structure is knitted with elastic yarn to form the inner curved surface of the support area; on the middle needles of the front and back needle beds, a double-sided tuck structure is knitted with high-modulus monofilament to form the interlayer of the support area; on the needles at the left and right edges of the front and back needle beds, a double-sided loop structure is knitted with both non-elastic and elastic yarns to form the left and right seam areas.

[0019] S4. Repeat the weaving process of step S2;

[0020] S5. Use non-elastic yarn and elastic yarn to knit a double-sided loop structure on all knitting needles to form a full row of stitched areas;

[0021] S6. Repeat the weaving process from S2 to S5 as needed, adjusting the number of rows woven in each step as required.

[0022] In one possible implementation, in step S3: the number of adjacent loops in the double-sided loop structure is greater than 2 stitches, and at least one loop is woven in each row of looped coils.

[0023] The beneficial effects of the technical solution provided in this application include at least the following:

[0024] The segmented arc-shaped spacer fabric provided in this application has both an arc-shaped surface and multiple segments. The arc surface can be easily attached to a cylindrical surface, and the multi-segment structure makes it easy for the fabric to bend and maintain the shape of the protected part. When subjected to external impact, the spacer layer can play a protective role. In addition, it is woven in one step using a computer flat knitting machine, which reduces the production process and avoids the performance loss of the spacer fabric caused by molding and cutting. Attached Figure Description

[0025] 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:

[0026] Figure 1 This shows a schematic diagram of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application;

[0027] Figure 2 A schematic diagram of the cross-sectional structure of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application is shown;

[0028] Figure 3 This paper shows a schematic diagram of the process partitioning of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application;

[0029] Figure 4 The diagram shows the weaving pattern of the support area, hollow area, and stitching area of ​​the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application;

[0030] Figure 5 A weaving diagram of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application is shown;

[0031] Figure 6 This paper shows a schematic diagram of the process partitioning of the segmented arc-shaped spacer fabric provided in Embodiment 2 of this application;

[0032] Figure 7 A physical image of the segmented arc-shaped spacer fabric provided in Embodiment 2 of this application is shown. Detailed Implementation

[0033] 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.

[0034] 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.

[0035] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0036] Example 1:

[0037] Figure 1 This illustration shows a schematic diagram of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application. Figure 2 A schematic cross-sectional view of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application is shown. The segmented arc-shaped spacer fabric includes an outer curved surface 1, an inner curved surface 2, and a spacer layer 3 for supporting the outer curved surface 1 and the inner curved surface 2, forming the spacer thickness of the fabric; wherein, the segmented arc-shaped spacer fabric is segmented in the longitudinal direction, and multiple segments can move between each other; the segmented arc-shaped spacer fabric is arc-shaped in the transverse direction, and is used to fit the protected part.

[0038] In this embodiment of the application, after the segmented arc-shaped spacer fabric is woven, the elastic yarns on the inner curved surface 2 shrink, the loops become smaller, and the distance between the loops also decreases, while the non-elastic yarns on the outer curved surface 1 do not shrink, making the fabric arc-shaped.

[0039] In this embodiment, the segmented arc-shaped spacer fabric has two segments with a spacer layer in the middle. The inner and outer surfaces of the segments are woven and sewn together by double-sided loop weave. After the fabric is bent into an arc shape, it is fixed in shape at 180-190°C for 50 seconds.

[0040] Furthermore, the segmented arc-shaped spacer fabric includes a support area, a hollow area, and a seaming area. The support area uses non-elastic yarn to weave the outer curved surface, elastic yarn to weave the inner curved surface, and high-modulus monofilament to weave the spacer layer. The hollow area uses non-elastic yarn to weave the outer curved surface, elastic yarn to weave the inner curved surface, and no spacer layer is woven. The seaming area uses non-elastic yarn and elastic yarn alternately to weave the outer and inner curved surfaces. The outer and inner curved surfaces of the support area and the hollow area are woven with a single-sided loop weave, the spacer layer of the support area is woven with a double-sided loop weave, and the seaming area is woven with a double-sided loop weave. Each support area constitutes a segment, and multiple segments are connected by the hollow area and the seaming area. Optionally, the outer curved surface is woven from 50-600D polyester or nylon yarn; the inner curved surface is woven from 50-600D polyester and spandex covered yarn, or nylon and spandex covered yarn; and the spacer layer is woven from polyester monofilament with a diameter of 0.3-2mm. Optionally, the central angle of the arc-shaped spacer fabric ranges from 30 to 180°, and the thickness of the spacer layer ranges from 5 to 25 mm.

[0041] Specifically, Figure 3 The diagram shows a process partitioning diagram of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application. The arrows in the diagram indicate the weaving direction of the fabric. The checkered pattern represents the support area 4, the diagonal pattern represents the hollow area 5, and the dotted pattern represents the stitching area 6. Figure 4 The diagram shows the weaving pattern of the support area, hollow area, and stitching area of ​​the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application. It shows the weaving of the support area 7, the hollow area 8, and the stitching area 9. In the diagram:

[0042] A indicates that the knitting row is woven using non-elastic yarn;

[0043] B indicates that the knitting row is woven using elastic yarn;

[0044] C indicates that the weaving row uses high-modulus monofilament weaving;

[0045] This indicates the stitches are gathered at the back of the needle bed;

[0046] This indicates that the needles are gathered at the front of the needle bed;

[0047] This indicates that the needles are looped on the back of the needle bed;

[0048] This indicates that the needle is looped on the front needle bed.

[0049] It is worth mentioning that this embodiment also provides a method for preparing a segmented arc-shaped spacer fabric. The method is used to prepare the aforementioned segmented arc-shaped spacer fabric, and the method employs a double-needle bed computerized flat knitting machine with an electronic needle selection device for knitting. The method includes:

[0050] Step S1: Use non-elastic yarn and elastic yarn to knit a double-sided loop structure on all knitting needles to form a full row of stitched areas;

[0051] Step S2: Use non-elastic yarn to knit a single-sided loop structure on the middle needle of the front needle bed to form the outer curved surface of the hollow area; use elastic yarn to knit a single-sided loop structure on the middle needle of the back needle bed to form the inner curved surface of the hollow area; use non-elastic yarn and elastic yarn to knit a double-sided loop structure on the left and right edge needles of the front and back needle beds to form the left and right seam areas.

[0052] Step S3: On the middle needle of the front needle bed, use non-elastic yarn to knit a single-sided loop structure to form the outer curved surface of the support area; on the middle needle of the back needle bed, use elastic yarn to knit a single-sided loop structure to form the inner curved surface of the support area; on the middle needles of the front and back needle beds, use high-modulus monofilament to knit a double-sided tuck structure to form the support area interlayer; on the left and right edge needles of the front and back needle beds, use non-elastic yarn and elastic yarn to knit a double-sided loop structure to form the left and right seam areas.

[0053] Step S4: Repeat the weaving process of step S2;

[0054] Step S5: Knit a double-sided loop structure on all the knitting needles using non-elastic yarn and elastic yarn to form a full row of stitched areas;

[0055] Step S6: Repeat the weaving process from steps S2 to S5 as needed, increasing or decreasing the number of rows woven in each step as required.

[0056] In step S3 above, the number of stitches between adjacent loops in the double-sided loop structure is greater than 2, and at least one loop is woven in each row of looped coils.

[0057] In detail, Figure 5 The diagram shows the knitting pattern of the segmented arc-shaped spacer fabric provided in Embodiment 1 of this application. The working stitch count is 40 stitches, with 4 stitches on the left and 4 stitches on the right for knitting the left and right seam areas. The knitting process for the middle 32 stitches is as follows:

[0058] Step 1, press Figure 4 The first and second rows of the weaving stitching area are woven together in two horizontal rows.

[0059] Step 2, press Figure 4 The hollow area is woven in the 3rd and 4th rows of the middle section, with a total of 3 horizontal columns woven;

[0060] Step 3, press Figure 4 The support area is woven in rows 5-11, with a total of 20 rows woven.

[0061] Step 4, press Figure 4 The hollow area is woven in rows 12 and 13, with a total of 3 horizontal rows woven;

[0062] Step 5, press Figure 4 The 14th and 15th rows of the weaving stitch area are woven together, with a total of 2 horizontal rows;

[0063] Step 6: Repeat the weaving process of steps 2-5 to obtain a segmented arc-shaped spacer fabric.

[0064] Example 2:

[0065] This embodiment is a variation of Embodiment 1. Figure 6 The diagram shows a process partitioning diagram of the segmented arc-shaped spacer fabric provided in Embodiment 2 of this application. The segmented arc-shaped spacer fabric provided in this embodiment includes 4 segments. Figure 6 The grid pattern in the middle represents the support area, according to... Figure 4 The weaving support area 7 is woven; the diagonal texture represents the hollow area, according to... Figure 4 The hollow area 8 is woven in; the dotted texture represents the seam area, according to... Figure 4 The knitting and sewing area 9 is knitted. This fabric is knitted on a double-needle bed computerized flat knitting machine. The non-elastic yarn is 500D nylon yarn, the elastic yarn is 400D nylon yarn plus 40 / 70 nylon-spandex covered yarn, and the high-modulus monofilament uses two 0.3 mm diameter polyester monofilaments. The specific knitting process is shown in Table 1 below:

[0066] Table 1:

[0067]

[0068]

[0069] Figure 7 The illustration shows a physical image of the segmented arc-shaped spacer fabric provided in Embodiment 2 of this application. The segmented arc-shaped spacer fabric woven by the above specific weaving process has an average density of 4 rows / cm in the transverse direction and 6.5 rows / cm in the longitudinal direction. The central angle corresponding to the large end arc is 148°, and the thickness of the support area is 1.6 cm.

[0070] 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 segmented arc-shaped spacer fabric, characterized in that, It includes an outer curved surface, an inner curved surface, and a spacer layer for supporting the outer curved surface and the inner curved surface; The segmented arc-shaped spacer fabric is segmented longitudinally, and multiple segments can move between each other; the segmented arc-shaped spacer fabric is arc-shaped transversely and is used to fit the protected part. The segmented arc-shaped spacer fabric includes a support area, a hollow area, and a sewing area; each support area constitutes a segment, and multiple segments are connected by the hollow area and the sewing area; the support area is woven with non-elastic yarn to form the outer curved surface, with elastic yarn to form the inner curved surface, and with high-modulus monofilament to form the spacer layer. The hollow area is woven with non-elastic yarn to form the outer curved surface and with elastic yarn to form the inner curved surface, without weaving the spacer layer; the sewing area is woven with non-elastic yarn and elastic yarn alternately to form the outer curved surface and the inner curved surface. The outer and inner curved surfaces of the support area and the hollow area are made of single-sided loop weave; the spacer layer of the support area is made of double-sided loop weave; and the suture area is made of double-sided loop weave.

2. The segmented arc-shaped spacer fabric according to claim 1, characterized in that, The outer curved surface is woven from 50-600D polyester or nylon yarn; the inner curved surface is woven from 50-600D polyester and spandex covered yarn, or nylon and spandex covered yarn; the spacer layer is woven from polyester monofilament with a diameter of 0.3-2mm.

3. The segmented arc-shaped spacer fabric according to claim 1, characterized in that, The central angle of the segmented arc-shaped spacer fabric ranges from 30 to 180°, and the thickness of the spacer layer ranges from 5 to 25 mm.

4. A method for preparing a segmented arc-shaped spacer fabric, the method being applicable to the segmented arc-shaped spacer fabric according to any one of claims 1 to 3, characterized in that, The method employs a double-needle bed computerized flat knitting machine with an electronic needle selection device for knitting, and the method includes: S1. Double-sided loop structure is knitted on all needles using non-elastic yarn and elastic yarn to form a full row of stitched areas; S2. On the middle needle of the front needle bed, a single-sided loop structure is knitted with non-elastic yarn to form the outer curved surface of the hollow area; on the middle needle of the back needle bed, a single-sided loop structure is knitted with elastic yarn to form the inner curved surface of the hollow area; on the left and right edge needles of the front and back needle beds, a double-sided loop structure is knitted with non-elastic yarn and elastic yarn to form the left and right seam areas. S3. On the middle needle of the front needle bed, a single-sided loop structure is knitted with non-elastic yarn to form the outer curved surface of the support area; on the middle needle of the back needle bed, a single-sided loop structure is knitted with elastic yarn to form the inner curved surface of the support area; on the middle needles of the front and back needle beds, a double-sided tuck structure is knitted with high-modulus monofilament to form the interlayer of the support area; on the needles at the left and right edges of the front and back needle beds, a double-sided loop structure is knitted with both non-elastic and elastic yarns to form the left and right seam areas. S4. Repeat the weaving process of step S2; S5. Use non-elastic yarn and elastic yarn to knit a double-sided loop structure on all knitting needles to form a full row of stitched areas; S6. Repeat the weaving process from S2 to S5 as needed, adjusting the number of rows woven in each step as required.

5. The method for preparing the segmented arc-shaped spacer fabric according to claim 4, characterized in that, In step S3: the number of stitches between adjacent loops of the double-sided loop structure is greater than 2 stitches, and at least one loop is woven in each row of looped coils.

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