Process design method for resisting down lodging of corduroy and corduroy fabric

Abstract

The invention belongs to the technical field of textiles, and particularly relates to a corduroy anti-fluff lodging process design method and a corduroy fabric, and the design method comprises the following steps: establishing a corduroy process library, and endowing each corduroy production process in the process library with a corresponding stripe density range; determining the stripe density of corduroy to be produced, comparing the stripe density with the stripe density range corresponding to each production process in the corduroy process library, and preliminarily determining a matched alternative production process; the number of the alternative production processes is judged, the minimum lengths, capable of being obtained through all the alternative production processes, of corduroy fluff are sorted, at least one minimum length with the smaller numerical value is selected, and the alternative production process corresponding to the minimum length is selected. The corduroy fabric with the shortest fluff can be obtained under the condition that the process is allowed, the fluff can be obtained through brushing after cutting and napping through felting and the like, and the problem of fluff lodging can be effectively solved by shortening the length of the fluff.

Description

Technical Field

[0001] The invention belongs to the technical field of textiles, and in particular relates to a process design method for preventing the pile from lodging of corduroy and corduroy fabric. Background Art

[0002] Traditional corduroy fabrics often have the phenomenon of "falling down and straightening the hair". This is mainly because the surface of corduroy is composed of dense hair, which is brushed in one direction and dyed and finished with water to form a certain direction of lodging. Under daily use or external friction, the hair is more likely to fall down, that is, to fall in one direction, thus forming the phenomenon of "falling down and straightening the hair". In this case, the following problems will occur: Due to the difference in light reflection, the straight and reverse hair will make the fabric show different tones at different angles. This phenomenon is particularly obvious during use. For example, after the surface of the clothing is rubbed or indented, the fallen area will appear brighter and whitish, affecting the overall aesthetics of the clothing. Once the corduroy hair falls down, it will form a "mark" that is difficult to recover automatically. The common recovery method requires manual combing or steam ironing, but in actual use, this method is time-consuming and labor-intensive, and cannot completely eliminate the indentation.

[0003] The phenomenon of corduroy falling flat not only affects the appearance, but also reduces the service life of the fabric to a certain extent. Frequent lying and recovery treatments can easily cause the pile to break or wear, affecting the durability of the fabric. Summary of the invention

[0004] The present invention provides a process design method for preventing the pile from lodging of corduroy and corduroy fabric, which can effectively solve the problems in the background technology.

[0005] To achieve the above object, the technical solution of the present invention is as follows: A process design method for preventing the pile from lodging of corduroy, comprising: Establishing a corduroy process library, and assigning a corresponding stripe density range to each corduroy production process in the process library; Determine the stripe density of the corduroy to be produced, and compare it with the stripe density range corresponding to each production process in the corduroy process library, and preliminarily determine a matching candidate production process; Determine the number of the alternative production processes. If the number is 0, interrupt the process design; if the number is 1, determine to adopt the alternative production process; if the number is greater than 1, perform the following steps: The minimum lengths of the corduroy fluff that can be obtained by each of the alternative production processes are sorted, at least one of the minimum lengths with a smaller value is selected, and the alternative production process corresponding to the minimum length is selected.

[0006] Furthermore, the process in the corduroy process library includes the following steps of obtaining the fluff: After one weft thread of the corduroy is woven in, at least one pile weft thread is woven in parallel in sequence, the floating length of the pile weft thread at least spans three warp threads, and a plurality of the weft threads and the pile weft threads are interwoven with the warp threads to form a cloth; The floating length of the pile weft is partially removed, and after the removal, the end of the remaining part of the pile weft stands upright relative to the pile roots, and the pile roots of adjacent pile wefts are staggered.

[0007] Furthermore, in the process of obtaining the villi, the following cutting tools are used, including: A fly needle having a connection point and two steel wires extending to one side at intervals relative to the connection point; A core strip fixedly connected to the connection portion and located between the two steel wires to divide the interval between the two steel wires into two areas; Two parallel tuft cutting blades are arranged corresponding to the fly needles, the tuft cutting blades are arranged by rotating the shaft body, and are inserted into the two areas one by one, and the core strip and the steel wire limit the tuft cutting blades on both sides of the axial direction of the shaft body; The flying needle is inserted into the bottom of the floating length of the pile weft and is arranged parallel to the width direction of the corduroy, and the length of the removed part is adjusted by the width of the core strip.

[0008] Furthermore, the design of the cutting tool comprises the following steps: Determining the outer width of the cutting tool and the width of the corduroy according to the parameters of the corduroy to be produced; Comprehensively determine the width range of the steel wire at least based on the outer width, the core strip width, the cutting velvet blade thickness and the velvet needle material, and select the steel wire width within the width range; Trial processing is performed by using the cutting tool with the outer width, core strip width and wire width, and recording the magnitude of the force exerted on the fly needle from the corduroy; The outer width is adjusted according to the magnitude of the applied force, and after the adjustment, the steel wire width is secondary selected within the width range to obtain an updated steel wire width; The trial machining is performed at least once until the force is within a set range.

[0009] Furthermore, the end of the steel wire is a round head structure.

[0010] Furthermore, the connection points are provided at two locations, respectively connecting the two ends of the two steel wires.

[0011] Furthermore, the process in the corduroy process library includes the following steps of obtaining the fluff: Weaving warp and weft into fabric; On one side of the fabric, part of the fibers on the surface of the weft yarns are pulled up to form a pile.

[0012] Furthermore, during the process of obtaining the fluff, densely packed needles or thorns are used to pull up the fibers.

[0013] Furthermore, the design of the thorn needle or thorn fruit includes the following steps: Determining the insertion depth, density and insertion angle of the pricking needle or pricking fruit according to the parameters of the corduroy to be produced; Conducting trial processing by using the needles or thorns with the insertion depth, density and insertion angle, and collecting the surface image of the processed corduroy; Identifying and analyzing at least one of the height consistency, density uniformity, directionality, fullness and color of the villi through the surface image; Adjusting the insertion depth, density and insertion angle according to the identification and analysis results; The trial processing is performed at least once until the identification and analysis results meet the requirements.

[0014] A corduroy fabric, wherein the process method of the corduroy fabric is obtained by the process design method for preventing the corduroy from falling over as described above.

[0015] The technical solution of the present invention can achieve the following technical effects: In the present invention, a corduroy fabric with shorter pile can be obtained if the process allows. By shortening the pile length, the problem of pile lodging can be effectively solved. Even if it is rubbed or squeezed by the outside world, the surface can remain flat, avoiding the visual effect of pile lodging. This method fundamentally reduces the probability of pile lodging and improves the appearance and durability of the fabric. This process design method has good applicability. Regardless of different stripe densities such as 12W, 14W or 18W, a suitable process can be quickly found through stripe density matching. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 A flow chart of the process design method for preventing the corduroy from falling down; Figure 2 It is the distribution map of ground weft, velvet weft and longitude and latitude; Figure 3 Design flow chart for cutting tools; Figure 4 A comparison diagram of the pile surface obtained by a cutting tool using a single cut pile blade and a cutting tool using a double cut pile blade; Figure 5 A schematic diagram of forming the pile by pulling up some fibers of the weft; Figure 6 A flow chart for forming pile by pulling up part of the weft fibers; Figure 7 This is a comparison of the pile surface obtained by cutting the pile and using the pile brushing method without cutting; Attached Figures: 1, warp; 2, pile weft; 3, ground weft; 4, weft; 41, pull-out portion; 42, retained portion. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0020] Embodiment 1 like Figure 1 As shown, a process design method for preventing the pile from falling over of corduroy comprises: A1: Establish a corduroy process library, and assign a corresponding stripe density range to each corduroy production process in the process library; when the number of corresponding production processes gradually increases, there will often be overlaps in the stripe density ranges that can be produced by different processes. Through this step, different production processes and stripe density ranges can be classified and managed, forming a set of standardized process data system; A2: Determine the stripe density of the corduroy to be produced, and compare it with the stripe density range corresponding to each production process in the corduroy process library to preliminarily determine the matching candidate production process; in this step, the stripe density is used as the basis for preliminary screening of the process, and accurate preliminary screening results can be obtained based on the process library; A3: Determine the number of alternative production processes. If the number is 0, interrupt the process design. This interruption mechanism can reduce subsequent errors and reduce the cost of trial and error. If the number is 1, determine to adopt the alternative production process. On the basis of subsequent implementation, it is often necessary to make detailed adjustments to the determined alternative production process. The adjustments here include but are not limited to fine-tuning of the length of the fluff, adjustment of the weaving tension, optimization of the finishing process, and adjustment of environmental factors. The adjusted optimized process can also be included in the process library as the data basis for subsequent process design. If the number is greater than 1, perform the following steps: A4: Sort the minimum lengths of corduroy fluff that can be obtained by each alternative production process, select at least one minimum length with a smaller value, and select the alternative production process corresponding to the minimum length; this step includes the case where only one alternative production process is selected, in which case the value of the minimum length corresponding to the alternative production process is the smallest; or, it also includes the case where several alternative production processes are selected, in which case the alternative production process corresponding to the minimum length ranked from large to small is selected. In order to comprehensively consider other aspects of the process and obtain a better final process path, the selection of multiple alternative production processes is better, which facilitates further detailed screening and adjustment based on other screening conditions; in this step, a second screening result is provided based on the minimum length of the fluff, and multi-layer screening makes the decision more scientific, accurate, and adaptable, and can meet the production needs of corduroy of different densities.

[0021] In the above method, if the process allows, a corduroy fabric with shorter pile can be obtained. By shortening the pile length, the pile lodging problem can be effectively solved. Even if it is rubbed or squeezed by the outside world, the surface can remain flat, avoiding the visual effect of the pile being inverted and straight. This method fundamentally reduces the probability of the pile lodging and improves the appearance and durability of the fabric. This process design method has good applicability. Whether it is different stripe densities such as 12W, 14W or 18W, the appropriate process can be quickly found through stripe density matching.

[0022] As an optimization method for the process library in the above process design method, Figure 2 As shown, the process in the corduroy process library includes the following steps for obtaining the fluff: After a weft thread of the corduroy is woven in, at least one pile weft 2 is woven in parallel, the floating length of the pile weft 2 at least spans three warp threads 1, and the multiple weft threads and the pile weft 2 are interwoven with the warp threads 1 to form a cloth; The floating length of the pile weft 2 is partially removed, and the end of the remaining part of the pile weft 2 after the removal stands upright relative to the pile roots, and the pile roots of adjacent pile wefts 2 are staggered.

[0023] By incorporating this method of obtaining fluff into the corduroy process library, the length of the fluff can be further reduced for some alternative processes. Through the rational use of the process library, the anti-lodging ability of the fluff of the obtained corduroy products can be effectively improved.

[0024] In this way, the weft thread serves as the ground weft 3 and is interwoven with the warp threads 1 in a plain weave to form a ground cloth. In order to ensure the stability of the ground cloth and thus enable the corduroy fabric to achieve the expected use effect, the number of pile wefts 2 corresponding to each ground weft 3 should not be too many. Two is a preferred implementation, and in this case, the floating length of the pile weft 2 spanning five warp threads 1 is a more appropriate implementation. Of course, this is only a preferred implementation and is not intended to limit the scope of protection of the present invention.

[0025] The interlaced part of the pile weft 2 and the warp 1 is used as the pile root to ensure that the pile is effectively fixed. In the corduroy weaving process, the cutting position of the pile weft 2 needs to be between the two warp lines 1. The floating length of the pile weft 2 at least spans five warp lines 1 to ensure that the pile parts at both ends of the pile root retain sufficient length, and different pile wefts 2 can be cut along the same straight line trajectory; Figure 2 The cutting distance D1 shown in the figure is the length of the removed part. After cutting along the dotted line trajectory on both sides of the distance, it can be ensured that the right side of the pile root in the lower right corner of the figure retains the length of the pile weft 2 spanning two warps 1, while the right side of the pile root closest to it retains the length of the pile weft 2 spanning one warp 1 due to misalignment. This length can ensure that the pile root can be effectively fixed within a certain range of stripe density; the final removed part can be discharged through the pile suction device.

[0026] It should be noted that in this preferred embodiment, since it is necessary to ensure sufficient pile weft floating length, the stripe density range should not be too large. In implementation, it is more suitable for medium-thick corduroy below 12W, with upright pile and clear and three-dimensional pit strips like reliefs. Of course, the stripe density threshold is only a preferred value. According to different process differences, the 12W threshold can also be adjusted within an appropriate range, all within the protection scope of the present invention. After implementation, the independent support and elasticity of the pile are enhanced by removing local floating length and setting the pile in an offset manner, thereby reducing the lodging phenomenon caused by friction or extrusion, significantly improving the anti-lodging ability of the fabric, and the erected pile ends bring a soft and comfortable touch. At the same time, the offset pile root structure reduces the mutual friction between the piles and improves the durability of the fabric.

[0027] As a preferred embodiment of the above, in order to further improve the corduroy process in the process library, in the above-mentioned step of obtaining the fluff, the tool form used is further improved. In the process of obtaining the fluff, the following cutting tools are used, including: The invention has a connection part, and a fly needle which leads two steel wires to one side at intervals relative to the connection part; a core strip which is fixedly connected to the connection part and is located between the two steel wires, dividing the interval between the two steel wires into two areas; two parallel pile cutting blades arranged corresponding to the fly needle, the pile cutting blades are arranged by rotating the shaft body, and are inserted into the two areas one by one, and the core strip and the steel wire limit the pile cutting blades on both sides of the axis direction of the shaft body, and the axis direction is arranged perpendicular to the length direction of the core strip; wherein, the connection part is preferably arranged with two parts, respectively connecting the two ends of the two steel wires, so that the fly needle structure is more stable. The fly needle is inserted into the bottom of the pile weft floating length, and is arranged parallel to the direction of the corduroy width, and part of the length is removed by adjusting the width of the core strip. During use, the pile cutting blade rotates and intermittently avoids the ground weft 3 to achieve the cutting of the pile weft 2. The flying needle squeezes the warp 1 on both sides through the friction surfaces on both sides, so that the corresponding floating length of the cut pile weft is tightened. Appropriate tension helps the pile weft 2 to be cut smoothly. The tension should not be too small to prevent the cloth from being too loose, the flying needle cannot pass straight, and it is easy to wander in the channel, resulting in uneven length of the pile; the interval between the two steel wires forms a total space to limit the two pile cutting blades, and the setting of the core strip in the total space forms an independent limiting area corresponding to each pile cutting blade, so that each pile cutting blade can cut along a stable straight line trajectory, thereby effectively ensuring the final quality of the product.

[0028] The cut pile blade performs a cutting action between two warp threads 1 limited by the steel wire and the core strip, and the specific position between the two warp threads 1 is adjusted by the width of the core strip, which is approximately equal to the length of the removed portion.

[0029] In size design, the wider the core strip, the shorter the pile. However, because the width of the pit strip is fixed, the steel wires fixing the cut pile blades at both ends will be thinner, and the cut pile blades cannot be fixed. In addition, when the width of the core strip exceeds a certain range, the pile is too short, the pile surface is difficult to be saturated, and groove marks are formed. In order to solve the above problems more comprehensively, as an optimal method, Figure 3 As shown, the design of the cutting tool includes the following steps: S1: Determine the outer width of the cutting tool and the width of the corduroy according to the parameters of the corduroy to be produced; S2: At least based on the outer width, core strip width, cutting blade thickness and fly needle material, comprehensively determine the width range of the steel wire. This range must effectively ensure that the limit of the steel wire to the cutting blade is stable, and the steel wire width is selected within the width range; S3: Trial processing is performed by using cutting tools with outer width, core strip width and wire width, and the magnitude of the force exerted on the fly needle from the corduroy is recorded; the force value can be collected by using a pressure sensor; specifically, a structure such as an extrusion block can be fixedly installed relative to the connection of the fly needle, and the fixed pressure sensing sheet can be squeezed. With the change of the force exerted on the fly needle, the output data of the pressure sensing sheet can be changed, and the required force magnitude can be obtained by conversion. Of course, the force can be obtained by other methods in the prior art, all of which are within the protection scope of the present invention; S4: The outer width is adjusted according to the magnitude of the applied force. The adjustment here is based on the applied force value that has been obtained, and a clear basis can be obtained. This adjustment can ensure that the flying needle is in a straight and non-swaying state. After the adjustment, the steel wire width is reselected within the width range to obtain an updated steel wire width. In the secondary selection process here, the steel wire width can be selected based on the new outer width, the state of the fabric being processed, and the state of the cutting velvet blade during the trial processing. Carry out at least one trial machining until the force is within the set range, and through gradual fine-tuning, finally achieve the optimal cutting tool state based on the process flow determined by the trial machining.

[0030] In the above optimization method, the fabric state includes but is not limited to: Fabric float recovery state: The float recovery state refers to whether the pile weft float can remain upright after cutting. A good float recovery state helps maintain the fullness and lodging resistance of the pile. After trial processing, the height of the float recovery is observed through optical measurement or image analysis system. Specifically, a laser rangefinder or high-resolution camera can be used to measure the average height and consistency of the pile to determine the float recovery effect. Fabric surface uniformity: Surface roughness meter or surface scanner can be used to detect surface uniformity and generate a three-dimensional surface profile map to analyze the flatness and uniformity after cutting; Fabric resilience: The resilience of the pile is tested by applying slight pressure to simulate friction, and a precision pressure sensor is used to record the height and time of the pile recovery to analyze the resilience performance.

[0031] Correspondingly, the status of the velvet cutting blade includes but is not limited to: Pile cutting blade temperature: Install a temperature sensor on the pleat cutting blade to monitor the temperature changes during the cutting process in real time. The temperature data can help determine whether the pleat cutting blade remains within a safe temperature range during long-term continuous cutting, thereby avoiding a decrease in cutting accuracy due to high temperature. Stability of the velvet blade: The shaking of the velvet blade during the cutting process can be monitored by an acceleration sensor or a vibration sensor, and the data can be fed back to the control system to ensure the stability of the velvet blade during the cutting process; Position and angle of the velvet cutting blade: A laser rangefinder or position sensor can be used to monitor the position of the velvet cutting blade in real time to ensure that the cutting depth meets the set value; at the same time, an angle sensor can be used to monitor the angle of the velvet cutting blade in real time to ensure the stability of the cutting angle.

[0032] As a preferred embodiment of the above, in order to avoid the steel wire affecting the corduroy fabric, the end of the steel wire is a rounded structure, so that the corduroy moves more smoothly relative to the flying needle without causing damage to the corduroy. Based on the same raw materials, the corduroy processed by the above optimized cutting pile tool is compared with the corduroy processed by using a single cutting pile blade without removing the pile weft floating length. Figure 4 As shown, the suede is more upright and has a stronger three-dimensional effect, just like the suede implanted on the surface of the thread card cloth.

[0033] Also for the purpose of improving the corduroy process in the process library, as another optimization method for the process library in the above process design method, such as Figure 5 and 6 As shown, the process in the corduroy process library includes the following steps for obtaining the fluff: The warp 1 and the weft 4 are interwoven into a fabric; on one side of the fabric, part of the fibers on the surface of the weft 4 are pulled up to form a pile. Figure 5 The pulled-out portion 41 and the retained portion 42 are shown respectively, and the retained portion 42 and the warp thread 1 together maintain the stability of the corduroy fabric surface.

[0034] In this way, in addition to achieving the purpose of controlling the length of the fluff within a certain range, the shortest limit of the fluff can be effectively reduced, and better product effects can be achieved. By adding this fluff acquisition method to the process library, a better data basis can be obtained in the process design process. When this preferred solution is implemented, long warp floats and long weft floats can be used to weave longitudinal velvet strips, forming corduroy with clear strip pits and arched velvet strips. In order to achieve the velvety feel of traditional corduroy, reasonable yarn count specifications and reasonable fabric structures should be selected. The warp float and weft float should not be too long, otherwise the yarn will be easily pulled out and arched. The weft float line width is 1.5mm~3.5mm, and the velvet effect is best. The fluff is fine, short and clear.

[0035] The corduroy obtained by this method of obtaining the pile can be applied to corduroy with a wider range of stripe density, such as 14W corduroy, compared with the corduroy obtained by removing two parts of the pile weft length in the above embodiment. Figure 7 As shown, the fabric features formed include: Visually, it has the same strong three-dimensional sense and warm velvet feeling as traditional cut-pile corduroy; the fluff is not cut, the fiber rigidity is weak, it feels more skin-friendly and softer than traditional corduroy, and the strength in the direction of the pile strips is 3 times that of traditional corduroy; the fluff will not fall off after countless frictions, and there is no reversed or straight pile, so the fluff is not easily flattened and turned white.

[0036] As a preferred embodiment of the above embodiment, during the process of obtaining the fluff, dense needles or thorns are used to pull up the fibers. The densely arranged needles or thorns can evenly pull the fabric surface, so that the density of the fluff on the entire surface of the fabric is consistent, avoiding sparse and uneven distribution of the fluff, and improving the visual aesthetics of the corduroy; the needles or thorns can control the height and density of the fluff when pulling up the fibers, which is suitable for generating shorter and denser fluff. By adjusting the density and penetration depth of the needles, the height of the fluff can be precisely controlled, thereby enhancing the texture of the fabric.

[0037] As a further optimization to enrich the process library, the design of needles or thorns includes the following steps: B1: Determine the insertion depth, density and insertion angle of the needle or thorn according to the parameters of the corduroy to be produced; in the implementation process, the insertion depth, density and insertion angle of the needle or thorn can be calculated by the system by inputting the parameters of the corduroy using the existing product design software or database in the field, or can also be determined preliminarily through human experience; B2: Test processing is performed by using needles or thorns with different insertion depths, densities and angles, and collecting surface images of the processed corduroy. Specifically, a high-definition camera or industrial camera can be used to collect images on the fabric surface. The camera should be equipped with a high-resolution lens to ensure that the details of the fluff can be clearly captured. Specifically, the camera can be photographed under constant lighting conditions to avoid image analysis errors caused by lighting changes. B3: Identify and analyze at least one of the following: the height consistency, density uniformity, directionality, fullness and color of the villi through surface images; In the specific identification and analysis process, height consistency can be determined by edge detection algorithms, such as the Canny algorithm, or by laser height scanning to analyze the height distribution of the villi and calculate the average height and standard deviation of each area. Density uniformity can be determined by texture analysis methods, such as the grayscale co-occurrence matrix, or object detection methods, to identify the number of villi per unit area and determine whether there is density unevenness. Directionality analysis can use direction detection algorithms, such as Sobel edge detection and Hough transform to evaluate the inclination direction of each villi and calculate the overall direction consistency. If the direction deviates too much, the insertion angle needs to be adjusted. Fullness and color can be determined by texture analysis and photometry technology to detect the surface smoothness and fullness of the villi, and a brightness analysis algorithm can be used to analyze the uniformity of the reflected brightness in different areas to determine whether the ideal gloss effect is achieved.

[0038] For the purpose of being more intelligent, a deep learning-based image classification model can be used to train a fabric quality detection model, and the image can be input into the model to automatically identify the above results. The above image recognition and analysis technologies can obtain solutions in the prior art, and the solutions obtained are all within the protection scope of the present invention; B4: Adjust the insertion depth, density and insertion angle according to the recognition and analysis results; specifically, the insertion depth of the needle can be adjusted through the pressure sensor and displacement sensor; the arrangement of the needles can be adjusted, and the needle distance can be changed to control the density. If the density is uneven, the number of needles can be appropriately increased or decreased; and for the adjustment of the insertion angle, the angle between the needle and the fabric surface is adjusted using the angle adjuster to ensure the upright effect of the fluff; Perform at least one trial processing until the identification and analysis results meet the requirements. After each trial processing, repeat the processes of B2 and B3 to analyze the surface image. If the analysis results do not meet expectations, continue to adjust the parameters according to the steps of B4 and perform the next round of trial processing until the results meet the standard requirements.

[0039] The parameters and image analysis results of each trial processing should be recorded in detail. A data set can be established. By analyzing the results of each trial, the impact of parameter changes on the fluff effect can be found out, and the parameter settings can be gradually optimized. These final parameter optimization results can be used as reference data for future production and incorporated into the process library for rapid call-up of subsequent products.

[0040] Embodiment 2 A corduroy fabric, the process method of the corduroy fabric is obtained by the process design method of the corduroy anti-pile lodging as described in Example 1. The technical effect that can be achieved by this corduroy fabric is as described in the above embodiment, and the problem of pile lodging can be effectively solved by shortening the pile length. Even if it is rubbed or squeezed by the outside world, the surface can remain flat, avoiding the visual effect of pile lodging. This method fundamentally reduces the probability of pile lodging and improves the appearance and durability of the fabric.

[0041] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A process design method for preventing the pile from falling over of corduroy, characterized in that: include: Establishing a corduroy process library, and assigning a corresponding stripe density range to each corduroy production process in the process library; Determine the stripe density of the corduroy to be produced, and compare it with the stripe density range corresponding to each production process in the corduroy process library, and preliminarily determine a matching candidate production process; Determine the number of the alternative production processes, and if the number is 0, interrupt the process design; If the number is equal to 1, it is determined to adopt the alternative production process; if the number is greater than 1, the following steps are performed: The minimum lengths of the corduroy fluff that can be obtained by each of the alternative production processes are sorted, at least one of the minimum lengths with a smaller value is selected, and the alternative production process corresponding to the minimum length is selected.

2. The process design method for preventing the corduroy from falling over according to claim 1 is characterized in that: The process in the corduroy process library includes the following steps of obtaining the fluff: After one weft thread of the corduroy is woven in, at least one pile weft thread is woven in parallel in sequence, the floating length of the pile weft thread at least spans three warp threads, and a plurality of the weft threads and the pile weft threads are interwoven with the warp threads to form a cloth; The floating length of the pile weft is partially removed, and after the removal, the end of the remaining part of the pile weft stands upright relative to the pile roots, and the pile roots of adjacent pile wefts are staggered.

3. The process design method for preventing the corduroy from falling over according to claim 2, characterized in that: During the villus harvesting process, the following cutting tools are used, including: A fly needle having a connection point and two steel wires extending to one side at intervals relative to the connection point; A core strip fixedly connected to the connection portion and located between the two steel wires to divide the interval between the two steel wires into two areas; Two parallel tuft cutting blades are arranged corresponding to the fly needles, the tuft cutting blades are arranged by rotating the shaft body, and are inserted into the two areas one by one, and the core strip and the steel wire limit the tuft cutting blades on both sides of the axis direction of the shaft body; The flying needle is inserted into the bottom of the floating length of the pile weft and is arranged parallel to the width direction of the corduroy, and the length of the removed part is adjusted by the width of the core strip.

4. The process design method for preventing the corduroy from falling over according to claim 3 is characterized in that: The design of the cutting tool comprises the following steps: Determining the outer width of the cutting tool and the width of the corduroy according to the parameters of the corduroy to be produced; Comprehensively determine the width range of the steel wire at least based on the outer width, the core strip width, the cutting velvet blade thickness and the velvet needle material, and select the steel wire width within the width range; Trial processing is performed by using the cutting tool with the outer width, core strip width and wire width, and recording the magnitude of the force exerted on the fly needle from the corduroy; The outer width is adjusted according to the magnitude of the applied force, and after the adjustment, the steel wire width is secondary selected within the width range to obtain an updated steel wire width; The trial machining is performed at least once until the force is within a set range.

5. The process design method for preventing the corduroy from falling over according to claim 4 is characterized in that: The end of the steel wire is a round head structure.

6. The process design method for preventing the corduroy from falling over according to claim 3, characterized in that: The connection points are provided with two locations, respectively connecting the two ends of the two steel wires.

7. The process design method for preventing the corduroy from falling over according to claim 1, characterized in that: The process in the corduroy process library includes the following steps of obtaining the fluff: Weaving warp and weft into fabric; On one side of the fabric, part of the fibers on the surface of the weft yarns are pulled up to form a pile.

8. The process design method for preventing the corduroy from falling over according to claim 7, characterized in that: During the villi harvesting process, densely packed needles or thorns are used to pull up the fibers.

9. The process design method for preventing the corduroy from falling over according to claim 7, characterized in that: The design of the thorn or thorn fruit comprises the following steps: Determining the insertion depth, density and insertion angle of the pricking needle or pricking fruit according to the parameters of the corduroy to be produced; Conducting trial processing by using the needles or thorns with the insertion depth, density and insertion angle, and collecting the surface image of the processed corduroy; Identifying and analyzing at least one of the height consistency, density uniformity, directionality, fullness and color of the villi through the surface image; Adjusting the insertion depth, density and insertion angle according to the identification and analysis results; The trial processing is performed at least once until the identification and analysis results meet the requirements.

10. A corduroy fabric, characterized in that: The process method of the corduroy fabric is obtained by the process design method for preventing the corduroy from falling over as described in any one of claims 1 to 9.

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