Manufacturing method of cut and printed blanket

Abstract

The invention relates to a method for manufacturing a cut and printed blanket. The method comprises the following steps: weaving and slitting: slitting a woven gray fabric by using a warp knitting slitting machine; during cloth cutting, parameters are adjusted and controlled according to the gauge of the woven grey cloth, and the cloth speed is controlled; then the grey cloth is subjected to shaping and lustring treatment, the grey cloth is subjected to brushing lustring and printing treatment, plain color piece dyeing or printing permeation is adopted for printing, finally, the blanket is subjected to brushing, lustring and ironing shearing, and finally, cloth cutting and edge covering are conducted to obtain a finished product. According to the preparation method, a pattern cutting process is adopted, traditional embossing is not needed during production, completeness of patterns can still be guaranteed after cleaning, and the hand feeling is smoother and softer. The embossing process is reduced, manpower and financial resources are saved, the production efficiency is improved, and energy is saved.

Description

Technical Field

[0001] The invention relates to a weaving method, in particular to a method for manufacturing a cut-out printed blanket. Background Art

[0002] Blankets are a traditional industry with a warming function. Compared with quilts, they are thinner. Currently, they are widely used in the wedding market, gift market and family. Today, there are mainly single-layer double-sided and laminated double-sided. Patterns include printing, carving, embossing, embroidery, etc. With the improvement of people's consumption level, people's demand for blankets is not only satisfied with its warmth retention, but also has higher requirements for decoration and comfort. At present, the blankets that want to make concave and convex patterns are all achieved through embossing. Embossed blankets have strict requirements on the blanket surface, embossing time, temperature, the position of the embossing plate, embossing stroke, etc. If you don't pay attention to the operation, it will affect the effect of the finished product. In response to this problem, we conducted market research and research on blankets, and made this high-end, high-quality cut-flower printed blanket. Since the cut-flower blanket can present a concave and convex pattern when it is cut, its pattern is printed on the grey cloth with a concave and convex feeling, and the finished blanket has a stronger three-dimensional sense after printing. At the same time, it solves the problems of uneven embossing depth and peeling of the finished embossed blanket.

[0003] In the existing technology, the process flow of printed embossed blankets has a cutting process and an embossing process. Printed embossed blankets are embossed after the printed blankets are arranged. When embossing, the embossing plate with the embossed pattern must be placed on the embossing machine first, and then the appropriate embossing temperature and time are adjusted according to the arranged blanket surface before embossing. Printed embossed blankets need to be operated after the blankets are printed. There is an extra process in the production process, which increases personnel expenses, labor consumption, time consumption, and is prone to produce by-products. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a new method for manufacturing a cut-out printed blanket in view of the deficiencies of the prior art. The preparation method of the present invention adopts a cut-out process, and does not require traditional embossing during production. The integrity of the pattern can still be ensured after cleaning, and the blanket is smoother and softer after hand finishing. The embossing process is reduced, manpower and financial resources are saved, production efficiency is improved, and energy is saved.

[0005] The technical problem to be solved by the present invention is achieved by the following technical solution. The present invention is a method for manufacturing a cut-out printed blanket, which is characterized by comprising the following steps: (1) Weaving and slitting: Blank weaving is done with a Raschel double needle bed warp knitting machine with 18 needles / inch, a needle bed gauge of 26mm-42mm, and a wool height of 10mm-18mm; a six-needle organization is used for full or half-interweaving. The woven grey fabric is slit by a warp knitting slitting machine. When slitting the fabric, the fabric feed position must be accurate, the cutting blade must be in the middle of the two layers of grey fabric, the blade of the slitting machine must be sharp, and the fabric feed tension must be uniform. The slitting pattern mold is fixed on the gantry of the slitting machine, and the servo system drives the mold to control the slitting pattern. The designed pattern is obtained by editing the fabric feeding distance, gantry position, swing speed, number of times, mode, and fabric feeding speed. When slitting the fabric, the parameters are adjusted and controlled according to the gauge of the woven fabric, and the fabric speed is controlled at 1.3m / min-6m / min; after slitting, the blanket fabric is rolled up to obtain the blanket fabric; (2) Shaping and ironing of white grey fabric White cloth shaping: Use a high-temperature shaping machine to pre-shape the blanket grey cloth at high temperature, so that the polyester yarn expands and loosens at high temperature; during shaping and stenting, the width of the grey cloth should be kept stable during stenting and shaping, and the speed should be controlled at 26m / min-36m / min; the temperature should be controlled at 160℃-170℃, and the pattern must be trimmed at the joints before sewing the joints when shaping the white cloth; Brushing and ironing of white cloth: Use a four-roller brushing machine to brush the white grey cloth, the cloth speed is controlled at 6m / min-8m / min, the ironing temperature is controlled at 200℃, the tension is controlled at 1N / m3-2.1N / m3 during the brushing process, the ironing distance is 59-70, and the bent fibers are straightened with ironing rollers; printing: Use solid color piece dyeing or printing penetration, the steps are as follows: Solid color piece dyeing: Use No. 3 emulsified paste to prepare the color paste, the color paste is mixed according to the ratio of 3.5KG emulsified paste and 96.5KG dye water, the pressure of the permeator is 30KPA on both sides, the pressure in the middle is 20KPA, the cloth speed is controlled at 20m / min-25m / min, the same variety of color paste concentration, permeation pressure, cloth speed is consistent, the fiber is fully loaded with pulp, and then hung on the rod, and then fixed with a steamer; the fixing temperature is 130℃, and the fixing time is controlled at 5-35 minutes according to the amount of dye used; Printing penetration: Before printing, it is necessary to select a suitable printing pattern according to the cut-out pattern to make a plate. The printing plate is made into 1-11 plates according to the pattern, and the plate-making mesh is 60-100 mesh; the color paste is prepared according to the weight of the grey cloth and the cut-out pattern, using No. 1 emulsified paste or No. 3 emulsified paste and No. 1 emulsified paste in a ratio of 1:10; then adjust the plate spacing according to the finished size of the required blanket; then lay the arranged white grey cloth velvet side up on the cloth support belt of the magnetic rod flat screen automatic printing machine, add the prepared color paste to both ends of the printing plate, and adjust the color according to the pattern color area. According to the weight of grey cloth, magnetic rods with diameters of 20MM, 25MM, 30MM and 40MM are used for scraping and printing respectively, with specifications of 200*240CM. When printing blankets below 3KG, one rod is used, and blankets above 3KG need to be scraped and printed with two rods. When printing with one rod, the rod speed is controlled at 30 Hz, and when printing with two rods, the rod speed is controlled at 50-60 Hz. When penetrating, the pressure of the penetrating machine should be adjusted according to the amount of sizing on the blanket surface after printing. The pressure of the penetrating machine is 1kPa-4kPa, and the sizing amount of double-layer blankets is controlled at 84-86%, and the sizing amount of single-layer blankets is controlled at 88%-92%; The printed grey fabric after penetration is subjected to steaming, color fixing, water washing and fabric shaping treatment; (4) Final brushing, ironing and cutting Post-finishing is the final processing of the blanket. The post-finishing procedures are: brushing, ironing, hot cutting, and finally cutting and hemming to get the finished product.

[0006] The manufacturing method of the cut-flower printed blanket described in the present invention has a further preferred technical solution: in step (1) weaving and slitting: the blank weaving raw materials are: super soft 150D / 144F, 200D / 144F and 250D / 96F raw materials, the base yarn is polyester full-drawn 100D / 96F; the weaving method is full-thread or half-thread.

[0007] The method for manufacturing a cut-flower printed blanket of the present invention has a further preferred technical solution as follows: in step (1) weaving and slitting: when weaving the blank, the weaving density is 13-15 turns / cm.

[0008] A further preferred technical solution of the method for manufacturing a cut-out printed blanket of the present invention is as follows: in step (3) of printing: The steaming color fixing method is: put the printed grey cloth after penetration into a pressure cooker for steaming and color fixing, and the steaming time is set to 10-30 minutes according to the depth of color; the color fixing temperature is 130℃.

[0009] A further preferred technical solution of the method for manufacturing a cut-out printed blanket of the present invention is as follows: in step (3) of printing: The washing method is as follows: the grey cloth after steaming and fixing is washed by an open-width washing machine, and the washing sequence is one clean water washing, glacial acetic acid degradation paste washing, two clean water rinsings, hydrosulfite and caustic soda decoloring washing, three clean water rinsings, and softening treatment; wherein the temperature of the one clean water washing is 20℃-25℃, the temperature of the glacial acetic acid washing is 20℃-25℃, and the molar concentration of the glacial acetic acid aqueous solution is 5-10mol / L; the temperature of the two clean water rinsings is 20℃-25℃; when hydrosulfite and caustic soda are used to decolorize, the molar concentration of the hydrosulfite and caustic soda aqueous solution is 5-10mol / L, and the washing temperature is 20-50℃; the temperature of the three clean water rinsings is 20-30℃; softener is used for softening treatment, the molar concentration of the softener aqueous solution is 3-6mol / L, and washing is performed at a temperature of 20-30℃.

[0010] A further preferred technical solution of the method for manufacturing a cut-out printed blanket of the present invention is as follows: in step (3) of printing: The method for shaping the printed cloth is as follows: after dehydrating the washed grey cloth, it is shaped, dried and stretched according to the needs of the finished product. The shaping temperature is 180°C, the width is 160-240cm, and the cloth feeding speed is 25-30m / min. After ensuring that the wool is completely dried and the size meets the requirements, the next finishing process can be carried out.

[0011] A method for manufacturing a cut-out printed blanket according to the present invention, a further preferred technical solution is: in the post-brush, hot-press and shearing process of step (4): The brushing method is: the rotation speed of the large cylinder of the 24-roller high-speed brushing machine is 70 rpm, the brushing speed is 12-14m / min, the cloth feeding tension 1 is 1.010N / m3, the tension 2 is 1.010N / m3, the tension 3 is 1.014N / m3, the cloth output tension is 1.023N / m3, the left brush brushing strength is 20-26, and the right brush brushing strength is 20-26.

[0012] A method for manufacturing a cut-out printed blanket according to the present invention, a further preferred technical solution is: in the post-brush, hot-press and shearing process of step (4): The ironing method is: ironing is mainly to straighten the fibers, eliminate the internal stress of the fibers, straighten the bent fibers, and evenly reflect light. Since polyester is relatively resistant to high temperatures, the ironing temperature is set relatively high, generally at 190-210°C, and the speed is 12-15m / min.

[0013] Compared with the prior art, the present invention has the following beneficial effects: The preparation method of the present invention adopts a cutting process, and the pattern is more diversified in design. It only needs to design a mold that needs the pattern and cut it through a cloth cutting machine to complete it. It is not necessary to draw the graphics first and then make the embossing plate like a traditional embossed blanket, and finally emboss the finished blanket, and the production cycle is relatively long. The present invention solves the problems of peeling of the embossed blanket surface and uneven embossing depth, eliminates the processes of embossing plate installation and preheating before embossing, and shortens the production cycle. The cut-flowered blanket can still ensure the integrity of the pattern after cleaning, and the feel is smoother and softer than the embossed blanket surface. Not embossing can save 3 workers, effectively alleviate the problem of difficulty in hiring, save personnel expenses, reduce production costs, and improve production efficiency. At the same time, the embossing of the embossed plate needs to be electrically heated. At present, 1400-1500 sides of the blanket can be embossed in 12 hours, and the electricity consumption is 0.2 yuan / side blanket. The cut-out blanket eliminates the embossing process and can save electricity costs by 0.2 yuan per side. It can increase production while reducing energy consumption, making it more energy-efficient and environmentally friendly.

[0014] The invention ensures the quality of the product by controlling the weaving structure and the cloth-cutting speed of the cut-pattern blanket, the pressure and cloth speed of solid-color piece dyeing, the speed and penetration pressure of the printing rod, and the speed and tension of the brush hair. DETAILED DESCRIPTION

[0015] The specific technical solutions of the present invention are further described below to help those skilled in the art further understand the present invention without limiting the rights thereof.

[0016] Embodiment 1, a method for manufacturing a cut-out printed blanket, comprising the following steps: (1) Weaving and slitting: Blank weaving is done with a Raschel double needle bed warp knitting machine, with a needle bed gauge of 26mm and a wool height of 10mm; six-needle organization is used for full or half-through organization; The warp knitting slitting machine is used to slit the woven grey cloth. When slitting the cloth, the cloth feeding position must be accurate, the cutting blade must be between the two layers of grey cloth, the blade of the slitting machine must be sharp, and the cloth feeding tension must be uniform. The slitting pattern mold is fixed on the gantry of the slitting machine, and the servo system drives the mold to control the slitting pattern. The designed pattern can be obtained by editing the cloth feeding distance, gantry position, swing speed, number of times, mode, and cloth feeding speed. When slitting the fabric, the parameters are adjusted and controlled according to the gauge of the woven fabric, and the fabric speed is controlled at 1.3m / min; after slitting, the blanket fabric is rolled up to obtain the blanket fabric; (2) Shaping and ironing of white grey fabric White cloth shaping: Use a high-temperature shaping machine to pre-shape the blanket grey cloth at high temperature, so that the polyester yarn expands and loosens at high temperature; during shaping and stretching, stretch according to design requirements and printing screen width. During the stretching and shaping process, the width of the grey cloth should be kept stable, and the speed should be controlled at 26m / min; the temperature should be controlled at 160℃, and the pattern must be cut at the joints before sewing when shaping the white cloth; Brushing and ironing of white cloth: Use a four-roller brushing machine to brush the white grey cloth, the cloth speed is controlled at 6m / min, the ironing temperature is controlled at 200℃, the tension is controlled at 1N / m3 during the brushing process, the ironing distance is 59, and the bent fibers are straightened with ironing rollers; printing: Use solid color piece dyeing or printing penetration, the steps are as follows: Solid color piece dyeing: Use No. 3 emulsified paste color paste, the color paste is mixed according to the ratio of 3.5KG emulsified paste and 96.5KG dye water, the pressure of the permeator is 30KPA on both sides, the pressure in the middle is 20KPA, the cloth speed is controlled at 20m / min, the same variety of color paste concentration, permeation pressure, cloth speed is consistent, the fiber is fully loaded with pulp, and then hung on the rod, and then fixed with a steamer; the fixing temperature is 130℃, and the fixing time is controlled at 5 minutes according to the amount of dye used; Printing penetration: Before printing, it is necessary to select a suitable printing pattern according to the cut-out pattern to make a plate. The printing plate is made into 1-11 plates according to the pattern, and the plate-making mesh is 60 mesh; the color paste is prepared according to the weight of the grey cloth and the cut-out pattern. No. 1 emulsified paste or No. 3 emulsified paste and No. 1 emulsified paste are mixed in a ratio of 1:10; then the plate spacing is adjusted and positioned according to the finished size of the required blanket; then the arranged white grey cloth is laid flat on the cloth support belt of the magnetic rod flat screen automatic printing machine with the velvet side facing up, and the prepared color paste is added to both ends of the printing plate, and the color paste is added according to the pattern. The pattern matching area and grey cloth weight are scraped and printed with magnetic rods of 20MM, 25MM, 30MM and 40MM in diameter respectively, with specifications of 200*240CM. When printing on blankets weighing less than 3KG, one rod is used, and when printing on blankets weighing more than 3KG, two rods are needed for scraping and printing. When printing on one rod, the rod speed is controlled at 30 Hz, and when printing on two rods, the rod speed is controlled at 50 Hz. When penetrating, the pressure of the penetrating machine should be adjusted according to the amount of sizing on the blanket surface after printing. The pressure of the penetrating machine is 1kPa, and the sizing amount of double-layer blankets is controlled at 84%, and the sizing amount of single-layer blankets is controlled at 88%; The printed grey fabric after penetration is subjected to steaming, color fixing, water washing and fabric shaping treatment; (4) Final brushing, ironing and cutting Post-finishing is the final processing of the blanket. The post-finishing procedures are: brushing, ironing, hot cutting, and finally cutting and hemming to get the finished product.

[0017] Step (1) in weaving and slitting: the raw materials for blank weaving are: super soft 150D / 144F, 200D / 144F and 250D / 96F raw materials, the base yarn is polyester full-drawn 100D / 96F; the weaving method is full-thread or half-thread.

[0018] In step (1) weaving and slitting: when weaving the blank, the weaving density is 13 turns / cm.

[0019] Step (3) During printing: The steaming color fixing method is: put the printed grey cloth after penetration into a pressure cooker for steaming and color fixing, and the steaming time is set to 10 minutes according to the color depth; the color fixing temperature is 130℃.

[0020] The washing method is as follows: the grey cloth after steaming fixation is washed by an open-width washing machine, and the washing sequence is one clean water washing, glacial acetic acid degradation paste washing, two clean water rinsings, hydrosulfite and caustic soda decoloring washing, three clean water rinsings, and softening treatment; wherein the temperature of the one clean water washing is 20°C, the temperature of the glacial acetic acid washing is 20°C, and the molar concentration of the glacial acetic acid aqueous solution is 5 mol / L; the temperature of the two clean water rinsings is 20°C; when hydrosulfite and caustic soda are used to decolorize, the molar concentration of the hydrosulfite and caustic soda aqueous solution is 5 mol / L, and the washing temperature is 20°C; the temperature of the three clean water rinsings is 20°C; softener is used for softening treatment, the molar concentration of the softener aqueous solution is 3 mol / L, and washing is performed at 20°C.

[0021] The method for shaping the printed cloth is as follows: after dehydrating the washed grey cloth, it is shaped, dried and stretched according to the needs of the finished product. The shaping temperature is 180°C, the width is 160cm, and the cloth feeding speed is 25m / min. After ensuring that the wool is completely dried and the size meets the requirements, the next finishing process can be carried out.

[0022] After step (4), brush, iron and cut: The brushing method is: the rotation speed of the large cylinder of the 24-roller high-speed brushing machine is 70 rpm, the brushing speed is 12m / min, the cloth feeding tension 1 is 1.010N / m3, the tension 2 is 1.010N / m3, the tension 3 is 1.014N / m3, the cloth output tension is 1.023N / m3, the left brush brushing strength is 20, and the right brush brushing strength is 20.

[0023] The ironing method is: ironing is mainly for straightening fibers, eliminating the internal stress of fibers, straightening bent fibers, and evenly reflecting light. Since polyester is relatively resistant to high temperatures, the ironing temperature is set relatively high, generally at 190°C and the speed is 12m / min.

[0024] Embodiment 2, a method for manufacturing a cut-out printed blanket, characterized in that it comprises the following steps: (1) Weaving and slitting: Blank weaving is done with a Raschel double needle bed warp knitting machine with 18 needles / inch, a needle bed gauge of 42mm, and a wool height of 18mm; a six-needle organization is used for full or half-interweaving. The warp knitting slitting machine is used to slit the woven grey cloth. When slitting the cloth, the cloth feeding position must be accurate, the cutting blade must be between the two layers of grey cloth, the blade of the slitting machine must be sharp, and the cloth feeding tension must be uniform. The slitting pattern mold is fixed on the gantry of the slitting machine, and the servo system drives the mold to control the slitting pattern. The designed pattern can be obtained by editing the cloth feeding distance, gantry position, swing speed, number of times, mode, and cloth feeding speed. When slitting the fabric, the parameters are adjusted and controlled according to the gauge of the woven fabric, and the fabric speed is controlled at 1.3m / min-6m / min; after slitting, the blanket fabric is rolled up to obtain the blanket fabric; (2) Shaping and ironing of white grey fabric White cloth shaping: Use a high-temperature shaping machine to pre-shape the blanket grey cloth at high temperature, so that the polyester yarn expands and loosens at high temperature; during shaping and stenting, the width of the grey cloth should be kept stable during stenting and the speed should be controlled at 36m / min; the temperature should be controlled at 170℃, and the pattern must be trimmed at the joints before sewing when shaping the white cloth; Brushing and ironing of white cloth: Use a four-roller brushing machine to brush the white grey cloth, the cloth speed is controlled at 8m / min, the ironing temperature is controlled at 200℃, the tension is controlled at 2.1N / m3 during the brushing process, the ironing distance is 70, and the bent fibers are straightened with ironing rollers; printing: Use solid color piece dyeing or printing penetration, the steps are as follows: Solid color piece dyeing: Use No. 3 emulsified paste color paste, the color paste is mixed according to the ratio of 3.5KG emulsified paste and 96.5KG dye water, the pressure of the permeator is 30KPA on both sides, the pressure in the middle is 20KPA, the cloth speed is controlled at 25m / min, the same variety of color paste concentration, permeation pressure, cloth speed is consistent, the fiber is fully loaded with pulp, and then hung on the rod, and then fixed with a steamer; the fixing temperature is 130℃, and the fixing time is controlled at 30 minutes according to the amount of dye used; Printing penetration: Before printing, it is necessary to select the appropriate printing pattern according to the cut-out pattern to make the plate. The printing plate is made into 1-11 plates according to the pattern, and the plate-making mesh is 100 mesh; the color paste is prepared according to the weight of the grey cloth and the cut-out pattern. No. 1 emulsified paste or No. 3 emulsified paste and No. 1 emulsified paste are mixed in a ratio of 1:10; then the plate spacing is adjusted and positioned according to the finished size of the required blanket; then the arranged white grey cloth is laid flat on the cloth support belt of the magnetic rod flat screen automatic printing machine with the velvet side facing up, and the prepared color paste is added to both ends of the printing plate. The pattern color matching area and grey cloth weight are scraped and printed with magnetic rods of 20MM, 25MM, 30MM and 40MM in diameter respectively, with specifications of 200*240CM. When printing on blankets weighing less than 3KG, one rod is used, and when printing on blankets weighing more than 3KG, two rods are used for scraping and printing. When printing on one rod, the rod speed is controlled at 30 Hz, and when printing on two rods, the rod speed is controlled at 60 Hz. When penetrating, the pressure of the penetrating machine should be adjusted according to the amount of sizing on the blanket surface after printing. The pressure of the penetrating machine is 4kPa, and the sizing amount of double-layer blankets is controlled at 86%, and the sizing amount of single-layer blankets is controlled at 92%; The printed grey fabric after penetration is subjected to steaming, color fixing, water washing and fabric shaping treatment; (4) Final brushing, ironing and cutting Post-finishing is the final processing of the blanket. The post-finishing procedures are: brushing, ironing, hot cutting, and finally cutting and hemming to get the finished product.

[0025] Step (1) in weaving and slitting: the raw materials for blank weaving are: super soft 150D / 144F, 200D / 144F and 250D / 96F raw materials, the base yarn is polyester full-drawn 100D / 96F; the weaving method is full-thread or half-thread.

[0026] In step (1) weaving and slitting: when weaving the blank, the weaving density is 15 turns / cm.

[0027] Step (3) During printing: The steaming color fixing method is: put the printed grey cloth after penetration into a pressure cooker for steaming and color fixing, and the steaming time is set to 10 minutes according to the color depth; the color fixing temperature is 130℃.

[0028] The washing method is as follows: the grey cloth after steaming fixation is washed by an open-width washing machine, and the washing sequence is one clean water washing, glacial acetic acid degradation paste washing, two clean water rinsings, hydrosulfite and caustic soda decoloring washing, three clean water rinsings, and softening treatment; wherein the temperature of the one clean water washing is 25°C, the temperature of the glacial acetic acid washing is 25°C, and the molar concentration of the glacial acetic acid aqueous solution is 10 mol / L; the temperature of the two clean water rinsings is 25°C; when hydrosulfite and caustic soda are used to decolorize, the molar concentration of the hydrosulfite and caustic soda aqueous solution is 10 mol / L, and the washing temperature is 50°C; the temperature of the three clean water rinsings is 30°C; softener is used for softening treatment, the molar concentration of the softener aqueous solution is 6 mol / L, and washing is performed at 30°C.

[0029] The method for shaping the printed cloth is as follows: after dehydrating the washed grey cloth, it is shaped, dried and stretched according to the needs of the finished product. The shaping temperature is 180°C, the width is 240cm, and the cloth feeding speed is 30m / min. After ensuring that the wool is completely dried and the size meets the requirements, the next finishing process can be carried out.

[0030] After step (4), brush, iron and cut: The brushing method is: the rotation speed of the large cylinder of the 24-roller high-speed brushing machine is 70 rpm, the brushing speed is 14m / min, the cloth feeding tension 1 is 1.010N / m3, the tension 2 is 1.010N / m3, the tension 3 is 1.014N / m3, the cloth output tension is 1.023N / m3, the left brush brushing strength is 26, and the right brush brushing strength is 26.

[0031] The ironing method is: ironing is mainly to straighten the fibers, eliminate the internal stress of the fibers, straighten the bent fibers, and evenly reflect light. Since polyester is relatively resistant to high temperatures, the ironing temperature is set relatively high, generally at 190-210°C, and the speed is 12-15m / min.

[0032] Embodiment 3, a method for manufacturing a cut-out printed blanket, characterized by comprising the following steps: (1) Weaving and slitting: Blank weaving is done with a Raschel double needle bed warp knitting machine with 18 needles / inch, a needle bed gauge of 32mm, and a wool height of 16mm; a six-needle organization is used for full or half-interweaving. The warp knitting slitting machine is used to slit the woven grey cloth. When slitting the cloth, the cloth feeding position must be accurate, the cutting blade must be between the two layers of grey cloth, the blade of the slitting machine must be sharp, and the cloth feeding tension must be uniform. The slitting pattern mold is fixed on the gantry of the slitting machine, and the servo system drives the mold to control the slitting pattern. The designed pattern can be obtained by editing the cloth feeding distance, gantry position, swing speed, number of times, mode, and cloth feeding speed. When slitting the fabric, the parameters are adjusted and controlled according to the gauge of the woven fabric, and the fabric speed is controlled at 1.3m / min-6m / min; after slitting, the blanket fabric is rolled up to obtain the blanket fabric; (2) Shaping and ironing of white grey fabric White cloth shaping: Use a high-temperature shaping machine to pre-shape the blanket grey cloth at high temperature, so that the polyester yarn expands and loosens under high temperature; during shaping and stretching, stretch according to design requirements and printing screen width. During the stretching and shaping process, the width of the grey cloth should be kept stable, and the speed should be controlled at 30m / min; the temperature should be controlled at 165℃, and the pattern must be cut evenly at the joints before sewing the joints when shaping the white cloth; Brushing and ironing of white cloth: Use a four-roller brushing machine to brush the white grey cloth, the cloth speed is controlled at 7m / min, the ironing temperature is controlled at 200℃, the tension is controlled at 1.5N / m3 during the brushing process, the ironing distance is 65, and the bent fibers are straightened with ironing rollers; printing: Use solid color piece dyeing or printing penetration, the steps are as follows: Solid color piece dyeing: Use No. 3 emulsified paste to prepare the color paste, the color paste is mixed according to the ratio of 3.5KG emulsified paste and 96.5KG dye water, the pressure of the permeator on both sides is 30KPA, the pressure in the middle is 20KPA, the cloth speed is controlled at 22m / min, the same variety of color paste concentration, permeation pressure, cloth speed is consistent, the fiber is fully loaded with pulp, and then hung on the rod, and then fixed with a steamer; the fixing temperature is 130℃, and the fixing time is controlled at 20 minutes according to the amount of dye used; Printing penetration: Before printing, it is necessary to select the appropriate printing pattern according to the cut-out pattern to make the plate. The printing plate is made into 1-11 plates according to the pattern, and the plate-making mesh is 80 mesh; the color paste is prepared according to the weight of the grey cloth and the cut-out pattern. No. 1 emulsified paste or No. 3 emulsified paste and No. 1 emulsified paste are mixed in a ratio of 1:10; then the plate spacing is adjusted and positioned according to the finished size of the required blanket; then the arranged white grey cloth is laid flat on the cloth support belt of the magnetic rod flat screen automatic printing machine with the velvet side facing up, and the prepared color paste is added to both ends of the printing plate, and the color paste is added according to the pattern. The pattern matching area and grey cloth weight are respectively printed with magnetic rods of diameter 20MM, 25MM, 30MM and 40MM, with specifications of 200*240CM. When printing on blankets weighing less than 3KG, one rod is used, and when printing on blankets weighing more than 3KG, two rods are used for printing. When printing on one rod, the rod speed is controlled at 30 Hz, and when printing on two rods, the rod speed is controlled at 55 Hz. When penetrating, the pressure of the penetrating machine should be adjusted according to the amount of sizing on the blanket surface after printing. The pressure of the penetrating machine is 3kPa, and the sizing amount of double-layer blankets is controlled at 85%, and the sizing amount of single-layer blankets is controlled at 90%. The printed grey fabric after penetration is subjected to steaming, color fixing, water washing and fabric shaping treatment; (4) Final brushing, ironing and cutting Post-finishing is the final processing of the blanket. The post-finishing procedures are: brushing, ironing, hot cutting, and finally cutting and hemming to get the finished product.

[0033] Step (1) in weaving and slitting: the raw materials for blank weaving are: super soft 150D / 144F, 200D / 144F and 250D / 96F raw materials, the base yarn is polyester full-drawn 100D / 96F; the weaving method is full-thread or half-thread.

[0034] In step (1) weaving and slitting: when weaving the blank, the weaving density is 14 turns / cm.

[0035] Step (3) During printing: The steaming color fixing method is: put the printed grey cloth after penetration into a pressure cooker for steaming and color fixing, and the steaming time is set to 30 minutes according to the color depth; the color fixing temperature is 130℃.

[0036] The washing method is as follows: the grey cloth after steaming fixation is washed by an open-width washing machine, and the washing sequence is one clean water washing, glacial acetic acid degradation paste washing, two clean water rinsings, hydrosulfite and caustic soda decoloring washing, three clean water rinsings, and softening treatment; wherein the temperature of the one clean water washing is 22°C for glacial acetic acid washing, and the molar concentration of the glacial acetic acid aqueous solution is 8 mol / L; the temperature of the two clean water rinsings is 22°C; when hydrosulfite and caustic soda are used to decolorize, the molar concentration of the hydrosulfite and caustic soda aqueous solution is 8 mol / L, and the washing temperature is 35°C; the temperature of the three clean water rinsings is 25°C; softener is used for softening treatment, the molar concentration of the softener aqueous solution is 4 mol / L, and washing is performed at 25°C.

[0037] The method for shaping the printed cloth is as follows: after dehydrating the washed grey cloth, it is shaped, dried and stretched according to the needs of the finished product. The shaping temperature is 180°C, the width is 240cm, and the cloth feeding speed is 30m / min. After ensuring that the wool is completely dried and the size meets the requirements, the next finishing process can be carried out.

[0038] After step (4), brush, iron and cut: The brushing method is: the rotation speed of the large cylinder of the 24-roller high-speed brushing machine is 70 rpm, the brushing speed is 12-14m / min, the cloth feeding tension 1 is 1.010N / m3, the tension 2 is 1.010N / m3, the tension 3 is 1.014N / m3, the cloth output tension is 1.023N / m3, the left brush brushing strength is 24, and the right brush brushing strength is 24.

[0039] The ironing method is: ironing is mainly to straighten the fibers, eliminate the internal stress of the fibers, straighten the bent fibers, and evenly reflect light. Since polyester is relatively resistant to high temperatures, the ironing temperature is set relatively high, generally at 200°C and the speed is 13m / min.

[0040] The method of the present invention produces a cut-flowered printed blanket, which utilizes the existing warp knitting machine plus a mold to cut the white grey cloth, and then finishes the white grey cloth. Because the grey cloth has an uneven pattern when it is cut, it is necessary to pay attention to the consistency of the size of the disk head, the consistency of the tissue tension, and the consistency of the tension of the cloth surface and the bottom wire during weaving, so as to avoid the "horizontal stripes", "vertical stripes" or folding phenomenon on the cloth surface, which affects the cut-flowered effect. During the cutting process, the cloth running distance, the amplitude, number, mode, speed, etc. of the gantry swing should be controlled. During the finishing, it is necessary to pay attention to brushing the wool surface completely, and the bottom wire should not be damaged at the low wool height to prevent the grey cloth from tearing. During the printing process, the thickness of the color paste and the amount of slurry should be strictly controlled. During the penetration, it is necessary to ensure that the high wool places penetrate to the bottom, and the low wool height places cannot squeeze the slurry. During the post-shaving shearing process, it is necessary to pay attention not to cut off the highest point of the pattern, so as to ensure the product quality.

Claims

1. A method for manufacturing a cut-out printed blanket, characterized in that: The steps include: (1) Weaving and slitting: Blank weaving is done with a Raschel double needle bed warp knitting machine with 18 needles / inch, a needle bed gauge of 26mm-42mm, and a wool height of 10mm-18mm; a six-needle organization is used for full or half-interweaving. The woven grey fabric is slit by a warp knitting slitting machine. When slitting the fabric, the fabric feed position must be accurate, the cutting blade must be in the middle of the two layers of grey fabric, the blade of the slitting machine must be sharp, and the fabric feed tension must be uniform. The slitting pattern mold is fixed on the gantry of the slitting machine, and the servo system drives the mold to control the slitting pattern. The designed pattern is obtained by editing the fabric feeding distance, gantry position, swing speed, number of times, mode, and fabric feeding speed. When slitting the fabric, the parameters are adjusted and controlled according to the gauge of the woven fabric, and the fabric speed is controlled at 1.3m / min-6m / min; after slitting, the blanket fabric is rolled up to obtain the blanket fabric; (2) Shaping and ironing of white grey fabric White cloth shaping: Use a high-temperature shaping machine to pre-shape the blanket grey cloth at high temperature, so that the polyester yarn expands and loosens at high temperature; during shaping and stenting, the width of the grey cloth should be kept stable during stenting and shaping, and the speed should be controlled at 26m / min-36m / min; the temperature should be controlled at 160℃-170℃, and the pattern must be trimmed at the joints before sewing the joints when shaping the white cloth; White cloth brushing and ironing: Use a four-roller brushing machine to brush the white grey cloth, the cloth speed is controlled at 6m / min-8m / min, the ironing temperature is controlled at 200℃, and the tension is controlled at 1N / m during the brushing process 3 -2.1N / m 3 , the ironing distance is 59-70, and the bent fibers are straightened with an ironing roller; printing: Use solid color piece dyeing or printing penetration, the steps are as follows: Solid color piece dyeing: Use No. 3 emulsified paste to prepare the color paste, the color paste is mixed according to the ratio of 3.5KG emulsified paste and 96.5KG dye water, the pressure of the permeator is 30KPA on both sides, the pressure in the middle is 20KPA, the cloth speed is controlled at 20m / min-25m / min, the same variety of color paste concentration, permeation pressure, cloth speed is consistent, the fiber is fully loaded with pulp, and then hung on the rod, and then fixed with a steamer; the fixing temperature is 130℃, and the fixing time is controlled at 5-35 minutes according to the amount of dye used; Printing penetration: Before printing, it is necessary to select a suitable printing pattern according to the cut-out pattern to make a plate. The printing plate is made into 1-11 plates according to the pattern, and the plate-making mesh is 60-100 mesh; the color paste is prepared according to the weight of the grey cloth and the cut-out pattern, using No. 1 emulsified paste or No. 3 emulsified paste and No. 1 emulsified paste in a ratio of 1:10; then adjust the plate spacing according to the finished size of the required blanket; then lay the arranged white grey cloth velvet side up on the cloth support belt of the magnetic rod flat screen automatic printing machine, add the prepared color paste to both ends of the printing plate, and adjust the color according to the pattern color area. According to the weight of grey cloth, magnetic rods with diameters of 20MM, 25MM, 30MM and 40MM are used for scraping and printing respectively, with specifications of 200*240CM. When printing blankets below 3KG, one rod is used, and blankets above 3KG need to be scraped and printed with two rods. When printing with one rod, the rod speed is controlled at 30 Hz, and when printing with two rods, the rod speed is controlled at 50-60 Hz. When penetrating, the pressure of the penetrating machine should be adjusted according to the amount of sizing on the blanket surface after printing. The pressure of the penetrating machine is 1kPa-4kPa, and the sizing amount of double-layer blankets is controlled at 84-86%, and the sizing amount of single-layer blankets is controlled at 88%-92%; The infiltrated printed grey fabric is subjected to steaming, color fixing, water washing and fabric shaping treatment; (4) Final brushing, ironing and cutting Post-finishing is the final processing of the blanket. The post-finishing procedures are: brushing, ironing, hot cutting, and finally cutting and hemming to get the finished product.

2. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: Step (1) in weaving and slitting: the raw materials for blank weaving are: super soft 150D / 144F, 200D / 144F and 250D / 96F raw materials, the base yarn is polyester full-drawn 100D / 96F; the weaving method is full-thread or half-thread.

3. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: In step (1) weaving and slitting: when weaving the blank, the weaving density is 13-15 turns / cm.

4. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: Step (3) During printing: The steaming color fixing method is: put the printed grey cloth after penetration into a pressure cooker for steaming and color fixing, and the steaming time is set to 10-30 minutes according to the depth of color; the color fixing temperature is 130℃.

5. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: Step (3) During printing: The washing method is as follows: the grey cloth after steaming and fixing is washed by an open-width washing machine, and the washing sequence is one clean water washing, glacial acetic acid degradation paste washing, two clean water rinsing, hydrosulfite and caustic soda decoloring washing, three clean water rinsing, and softening treatment; wherein the temperature of the one clean water washing is 20℃-25℃, the temperature of the glacial acetic acid washing is 20℃-25℃, and the molar concentration of the glacial acetic acid aqueous solution is 5-10mol / L; the temperature of the two clean water rinsing is 20℃-25℃; when hydrosulfite and caustic soda are used to decolorize, the molar concentration of the hydrosulfite and caustic soda aqueous solution is 5-10mol / L, and the washing temperature is 20-50℃; the temperature of the three clean water rinsings is 20℃-30℃; softener is used for softening treatment, the molar concentration of the softener aqueous solution is 3-6mol / L, and washing is performed at a temperature of 20-30℃.

6. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: Step (3) During printing: The method for shaping the floral cloth is as follows: after dehydrating the washed grey cloth, it is shaped, dried and stretched according to the needs of the finished product. The shaping temperature is 180°C, the width is 160-240cm, and the cloth feeding speed is 25-30m / min.

7. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: After step (4), brush, iron and cut: The brushing method is: the rotation speed of the large cylinder of the 24-roller high-speed brushing machine is 70 rpm, the brushing speed is 12-14 m / min, and the cloth tension 1 is 1.010 N / m 3 , Tension 2 is 1.010N / m 3 , tension 3 is 1.014N / m 3 , the cloth tension is 1.023N / m 3 , the bristle strength of the left brush is 20-26, and the bristle strength of the right brush is 20-26.

8. The method for manufacturing a cut-out printed blanket according to claim 1, characterized in that: After step (4), brush, iron and cut: The ironing method is: the ironing temperature is 190-210℃, and the speed is 12-15m / min.