Stock solution coloring super-thick warm-keeping integrated fabric, weaving process and leggings

Abstract

The invention provides a dope-dyed super-thick warm-keeping integrated fabric, a weaving process and leggings, and belongs to the technical field of fabric weaving. The dope-dyed super-thick warm-keeping integrated fabric is woven by a double-sided circular knitting machine and is formed by weaving first yarn, second yarn, third yarn and fourth yarn according to a two-way circulation weaving method; wherein a first yarn and a second yarn are adopted in the first path of the two-path cyclic weaving method, and a third yarn and a fourth yarn are adopted in the second path of the two-path cyclic weaving method; the first yarns and the third yarns are 75D-200D DTY (Draw Textured Yarn) stock solution polyester or chinlon; and the second yarn and the fourth yarn are E70-E200D original liquid ammonia nylon. The 75D-200DDTY stock solution terylene or chinlon and E70-E200D original liquid ammonia nylon are colored and can be directly woven into the fabric, coloring treatment is not needed, the dyeing process is omitted, more than 95% of water and pollution discharge can be reduced, and meanwhile, the fabric can be integrally formed through yarn weaving, so that the fabric is skin-friendly, comfortable, free, breathable and excellent in elasticity, and the service life of the fabric is prolonged. The wearing is durable, and excellent wearing experience is provided for users.

Description

Technical Field

[0001] The present disclosure belongs to the technical field of fabric weaving, and particularly relates to a one-piece fabric with original liquid coloring, ultra-thick and warm, a weaving process thereof, and leggings. Background Art

[0002] The printing and dyeing industry, which consumes a large amount of water and energy, has formulated corresponding standards for the fresh water intake and wastewater discharge of per unit product of printing and dyeing. In particular, the implementation of the pollutant discharge permit system has forced many printing and dyeing factories to carry out technological innovations, such as using small-bath ratio dyeing equipment or applying high fixation rate dyes, short-process dyeing and finishing processes, etc. The original liquid coloring fiber has advantages that cannot be compared with the traditional dyeing process in terms of energy conservation and emission reduction, color light stability, color fastness, and production energy consumption. The original liquid coloring directly omits the dyeing process in dyeing and finishing, basically has no wastewater discharge, and at the same time has high dye adhesion and extremely high color fastness.

[0003] On the market, the thickened leggings for autumn and winter are made by gluing two pieces of fabric together, which will cause poor fabric opening, unnatural stretching, slipping down when wearing, tight binding, airtightness, discomfort to users. At the same time, the glue will come off after washing, and the wearing durability is poor. Summary of the Invention

[0004] The present disclosure aims to solve at least one of the technical problems existing in the prior art, and provides a one-piece fabric with original liquid coloring, ultra-thick and warm, a weaving process thereof, and leggings.

[0005] On the one hand, the present disclosure provides a one-piece fabric with original liquid coloring, ultra-thick and warm, which is woven by a double-sided circular knitting machine and formed by knitting the first yarn, the second yarn, the third yarn and the fourth yarn according to a two-way circulation knitting method; wherein,

[0006] The first way of the two-way circulation knitting method uses the first yarn and the second yarn, and the second way uses the third yarn and the fourth yarn;

[0007] The first yarn and the third yarn are 75D - 200D DTY original liquid polyester or nylon;

[0008] The second yarn and the fourth yarn are E70 - E200D original liquid spandex.

[0009] Optionally, the 75D - 200D DTY original liquid polyester or nylon is 75D - 200D thick-denier polyester or nylon that has been subjected to coloring treatment.

[0010] Optionally, the E70 - E200D original liquid spandex is 75D - 200D thick-denier spandex that has been subjected to coloring treatment.

[0011] Another aspect of the present disclosure provides a weaving process for preparing the above-described undyed thick and warm integrated fabric, and the weaving process includes:

[0012] Obtaining a first yarn and a third yarn of 75D - 200D DTY undyed polyester or nylon;

[0013] Obtaining a second yarn and a fourth yarn of E70 - E200D undyed spandex;

[0014] Using the first yarn and the second yarn as the first - path raw materials, and the third yarn and the fourth yarn as the second - path raw materials, and performing fabric knitting on the two - path raw materials by a double - sided circular knitting machine to form an undyed thick and warm integrated fabric.

[0015] Optionally, the double - sided circular knitting machine is a 20G - 32G double - sided circular knitting machine.

[0016] Optionally, the number of needles of the fabric is 34, the width of the fabric is 6.5 cm, and the gram weight of the fabric is 100G.

[0017] Optionally, the obtaining of the first yarn and the third yarn of 75D - 200D DTY undyed polyester includes:

[0018] Drying PET chips with a specification of 75D - 200D, and uniformly mixing color masterbatch with the dried PET chips to obtain a mixed material;

[0019] Putting the mixed material into a screw extruder, heating and melt - extruding it to obtain a molten material;

[0020] Extruding the molten material through the fine holes of a spinneret to form a thin stream, and cooling and solidifying it into a filament in a spinning channel;

[0021] Performing single - stage or multi - stage stretching on the filament on a stretching machine, and heating the stretched filament to form 75D - 200D DTY undyed polyester.

[0022] Optionally, the obtaining of the first yarn and the third yarn of 75D - 200D DTY undyed nylon includes:

[0023] Pre - treating the raw materials for producing DTY nylon, and uniformly mixing color masterbatch with the pre - treated raw materials to obtain a mixed material;

[0024] Putting the mixed material into a polymerization reactor, and performing a polymerization reaction under high temperature, the action of a catalyst and an auxiliary agent to form a nylon polymer and gradually condense it into nylon particles;

[0025] Heating the nylon particles to high - temperature melting, extruding and stretching them through a spinning machine to form initial fibers;

[0026] The initial fibers are low-drawn and high-temperature heat-set, and the set fibers are preheated to obtain 75D-200DDTY stock nylon.

[0027] Optionally, the step of obtaining the second yarn and the fourth yarn of E70-E200D liquid spandex comprises:

[0028] Polytetramethylene ether glycol and diphenylmethane diisocyanate are used as main raw materials and pretreated, polytetramethylene ether glycol and diphenylmethane diisocyanate are mixed, and prepolymerized under certain temperature conditions to generate a prepolymer containing isocyanate groups (-NCO) at both ends of the molecule;

[0029] The prepolymer is fully dissolved to obtain a prepolymer solution, the prepolymer solution is transferred to a polymerization reactor, stirred evenly, and a mixed amine DMAC solution of a chain extender and a terminator is added in a controlled manner to perform chain extension and chain termination reactions to obtain a polymer solution;

[0030] In the process of continuously transferring the polymer solution continuously generated in the polymerization reactor into the stirring tank, quantitatively adding the pre-prepared masterbatch solution into the stirring tank, fully stirring and mixing, so that the masterbatch is evenly dispersed in the polymer solution, and the spandex spinning stock solution is obtained;

[0031] The spandex spinning stock solution is woven into E70-E200D stock spandex by adopting a spinning forming process.

[0032] Another aspect of the present disclosure provides a liquid-dyed, ultra-thick, warm-keeping integrated leggings, which are formed from the fabric described above.

[0033] The present disclosure proposes a liquid-dyed, ultra-thick, warm-keeping integrated fabric, a weaving process, and leggings. The liquid-dyed, ultra-thick, warm-keeping integrated fabric is woven by a double-sided large circular machine and is formed by weaving a first yarn, a second yarn, a third yarn, and a fourth yarn according to a two-way circular knitting method; wherein, the first route of the two-way circular knitting method uses the first yarn and the second yarn, and the second route uses the third yarn and the fourth yarn; the first yarn and the third yarn are 75D-200DDTY liquid polyester or nylon; the second yarn and the fourth yarn are E70-E200D liquid spandex. The 75D-200DDTY liquid polyester or nylon and E70-E200D liquid spandex disclosed in the present disclosure have been dyed and can be directly woven into fabrics without dyeing treatment, eliminating the dyeing process, and can reduce water use and sewage discharge by more than 95%. At the same time, the above-mentioned yarn weaving can make the fabric integrally formed, making the fabric skin-friendly and comfortable, free and breathable, excellent in elasticity, and durable to wear, giving users an excellent wearing experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1Flow chart of the weaving process of the stock solution colored ultra-thick warm integrated fabric according to the specific embodiment of the present disclosure;

[0035] Figure 2 Schematic diagram of the weaving route of the weaving process of the stock solution colored ultra-thick warm integrated fabric according to the specific embodiment of the present disclosure. Specific embodiment

[0036] To enable those skilled in the art to better understand the technical solutions of the present disclosure, the present disclosure will be further described in detail below with reference to the drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present disclosure, which are a part of the embodiments of the present disclosure, rather than all the embodiments. Based on the embodiments of the present disclosure, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present disclosure.

[0037] On the one hand, the present disclosure provides a stock solution colored ultra-thick warm integrated fabric, which is woven by a double-sided circular knitting machine and formed by knitting the first yarn, the second yarn, the third yarn and the fourth yarn according to the two-way circulation knitting method; wherein, the first way of the two-way circulation knitting method uses the first yarn and the second yarn, and the second way uses the third yarn and the fourth yarn; the first yarn and the third yarn are 75D-200D DTY stock solution polyester or nylon; the second yarn and the fourth yarn are E70-E200D stock solution spandex.

[0038] In this embodiment, the 75D-200D DTY stock solution polyester or nylon and the E70-E200D stock solution spandex have been subjected to coloring treatment, and the fabric can be directly woven.

[0039] There is no need for coloring treatment, and the dyeing process is omitted, which can reduce the water consumption and sewage discharge by more than 95%.

[0040] At the same time, the above-mentioned yarn weaving can make the fabric integrally formed, making the fabric skin-friendly, breathable, excellent in elasticity, durable in wearing and giving users an excellent wearing experience.

[0041] In some preferred embodiments, the 75D-200D DTY stock solution polyester or nylon is the 75D-200D thick polyester or nylon that has been subjected to coloring treatment. That is to say, the 75D-200D thick polyester or nylon is used as the raw material, and after coloring treatment, it forms 75D-200D DTY stock solution polyester.

[0042] In other preferred embodiments, the E70-E200D stock solution spandex is the 75D-200D thick spandex that has been subjected to coloring treatment. Similarly, the 75D-200D thick spandex is used as the raw material, and after coloring treatment, it forms E70-E200D stock solution spandex, which is directly formed into yarn for weaving the fabric.

[0043] As shown Figure 1 in the figure, on the other hand, the present disclosure proposes a weaving process S100 for preparing the above-described stock solution-colored ultra-thick and warm integrated fabric, and the weaving process includes the following steps S110 to S130:

[0044] S110. Obtain the first yarn and the third yarn of 75D-200D DTY stock solution polyester or nylon.

[0045] In some preferred embodiments, obtaining the first yarn and the third yarn of 75D-200D DTY stock solution polyester includes:

[0046] Dry the PET chips with a specification of 75D-200D, mix the color masterbatch evenly with the dried PET chips to obtain a mixed material;

[0047] Put the mixed material into a screw extruder, heat it to above the melting point of the PET chips to make them melt, rotate the screw to push the material forward and further mix, and the pigments in the color masterbatch are evenly dispersed in the molten PET;

[0048] Extrude the molten material from the fine holes of the spinneret to form a thin stream, and cool and solidify it into a filament in the spinning channel;

[0049] The filament is subjected to single-stage or multi-stage stretching on a stretcher, and the stretching ratio is controlled so that the fiber reaches the target linear density (75D-200D). At the same time, the fiber orientation degree and strength are improved. The stretched filament is heated by a hot box and subjected to false twist deformation through a false twister to endow the fiber with fluffiness and elasticity, forming 75D-200D DTY stock solution polyester.

[0050] In some other preferred embodiments, obtaining the first yarn and the third yarn of 75D-200D DTY stock solution nylon includes:

[0051] Prepare raw materials for producing DTY nylon, such as caprolactam and diol, etc., and perform pretreatment, including emulsification, dehydration, distillation of caprolactam, and dehydration and purification of diol, etc., to ensure the quality and purity of the raw materials;

[0052] Mix the color masterbatch evenly with the pretreated raw materials to obtain a mixed material;

[0053] Put the mixed material into a polymerization reactor, and carry out a polymerization reaction under high temperature and the action of a catalyst and an auxiliary agent to form a nylon polymer and gradually agglomerate into nylon particles;

[0054] Heat the nylon particles to high temperature and melt them, extrude and stretch them into fine fibers through a spinning machine to obtain initial fibers, and precisely control the spinning temperature and stretching speed to ensure the fiber quality and strength;

[0055] The initial fibers are drawn at a low magnification and heat-set at a high temperature. Then, the heat-set fibers are pre-heated to eliminate internal stress and stabilize the coiling curvature. By drawing with a roller speed difference, the macromolecular orientation degree and the filament strength are improved. False twist deformation is carried out using a friction spindle group, etc., to endow the fibers with fluffiness and elasticity, and 75D - 200D DTY undrawn nylon is produced.

[0056] It should be noted that the masterbatch includes dyes, carrier resins, dispersants, additives, etc. Among them, the dyes can be selected according to actual needs, including organic pigments and inorganic pigments, such as phthalocyanine blue, azo pigments, etc. The carrier resin can be a resin with good compatibility such as spandex. Commonly used are polyester-type or polyether-type resins, which can ensure that the masterbatch is evenly mixed with the spandex raw materials during subsequent processing and will not have an adverse impact on the performance of the spandex. The dispersant can be polyethylene, stearic acid and its salts, etc. The additives can be selected according to actual needs. For example, antioxidants, light stabilizers and other auxiliaries are added to improve the performance of the masterbatch and the final spandex fiber, such as improving the aging resistance and light resistance.

[0057] S120. Obtain the second yarn and the fourth yarn of E70 - E200D undrawn spandex.

[0058] Specifically, polytetramethylene ether glycol and diphenylmethane diisocyanate are used as the main raw materials and are pre-treated. Polytetramethylene ether glycol and diphenylmethane diisocyanate are mixed and subjected to a pre-polymerization reaction under certain temperature conditions to generate a prepolymer with isocyanate groups (-NCO) at both ends of the molecule.

[0059] The prepolymer is fully dissolved to obtain a prepolymer solution. The prepolymer solution is transferred to a polymerization reactor, stirred evenly, and a mixed amine DMAC solution containing a chain extender and a terminator is added while controlling, and chain growth and chain termination reactions are carried out to obtain a polymer solution.

[0060] During the process of continuously transferring the polymer solution continuously generated in the polymerization reactor into the stirring tank, a pre-prepared masterbatch solution is quantitatively added into the stirring tank and stirred fully to make the masterbatch evenly dispersed in the polymer solution to obtain a spandex spinning dope.

[0061] The spandex spinning dope is woven into E70 - E200D undrawn spandex by a spinning and forming process.

[0062] It should be noted that the masterbatch in this step S120 is the same as that in step S110, and the specific components can be selected according to actual needs.

[0063] The masterbatch method adopted in this embodiment is a method of obtaining colored fibers by adding masterbatch during the spinning process according to the fiber color requirements. In this embodiment, the masterbatch and chip mixing method is adopted, that is, the masterbatch and conventional chips are directly mixed according to a certain addition ratio, mixed and dried by a drying device, and melt-mixed in a screw extruder for spinning to obtain colored fibers, saving the subsequent dyeing process of the fabric.

[0064] S130. The first yarn and the second yarn are used as the first raw material, and the third yarn and the fourth yarn are used as the second raw material. A double-sided circular knitting machine is used to knit the two raw materials into a fabric to form a one-piece fabric with original liquid coloring and ultra-thick warmth retention.

[0065] Specifically, as Figure 2 shown, a 20G - 32G double-sided circular knitting machine is used to weave the above raw materials. The yarn is introduced into the needle hook from each yarn feeding port and pulled to the center of the needle cylinder. After all the yarns are threaded, they are integrated into a bundle, and a knot is tied after ensuring uniform tension. The knot is passed through the take-up shaft of the cloth winding machine and tied tightly to the cloth winding roller. Jog the machine in "slow speed" to check the opening of the knitting needle tongue and the normal feeding of the yarn. Use a brush for assistance if necessary. Open the cloth at a low speed. After the fabric is long enough, install a cloth support frame, pass it evenly through the take-up shaft of the cloth winding machine, and then the cloth can be lowered relatively quickly. After the machine knits normally, let the positive yarn feeding device participate in yarn feeding, adjust the yarn tension evenly with a tensioner, and then the machine can run at high speed for knitting. Knit the fabric according to the set two-way raw material input (Route 1: the first yarn and the second yarn; Route 2: the third yarn and the fourth yarn).

[0066] During the knitting process, the knitting needles perform loop-forming movements, including yarn clearing (the knitting needle rises, the old coil in the needle hook moves downward, causing the needle tongue to turn down and open the needle orifice, and the old coil moves to the needle bar), yarn laying (the yarn is laid in the needle hook), closing the orifice, looping (the knitting needle descends, and the old coil is looped over the needle tip), yarn bending (the knitting needle descends, and the newly laid yarn is bent), doffing (the old coil is doffed from the needle tip and looped over the newly bent yarn coil), loop forming (the knitting needle descends to the lowest point to form a coil), and pulling (pushing the old coil and the new coil to the back of the needle), etc. Adjust the warp and weft yarn tensions in a timely manner according to the fabric situation. For example, adjust the warp yarn tension by adjusting the height of the back beam (when the back beam moves up, the tension of the lower layer of the shed becomes larger; when the back beam moves down, the tension of the lower layer of the shed becomes smaller, and the tension of the upper layer becomes larger); adjust the weft yarn tension by adjusting the nut of the tension disc on the weft break stop device, and finally knit a fabric weighing 340 - 700 grams.

[0067] The manufacturing process of this embodiment retains the natural elasticity of the fabric itself, reduces the processes of weaving and dyeing two pieces of fabric and the process of gluing two pieces of fabric together, shortens the weaving process, reduces the restraint on the fabric, and makes users feel more comfortable when wearing. This structure is more firm, not easily worn or deformed, and more durable. It stores the heat emitted by the human body and transfers it back to the human body in the form of radiant heat to achieve a warming effect, and at the same time has antistatic properties.

[0068] On the other hand, the present disclosure provides an all-in-one thick warm base layer leggings with stock solution coloring, which is formed of the fabric described above, has excellent color fastness, natural elasticity, and is not easily out of gear.

[0069] The present disclosure provides an all-in-one thick warm fabric with stock solution coloring, its weaving process, and leggings, which have the following beneficial effects compared with the prior art:

[0070] First, the present disclosure makes the fabric integrally formed by improving the machine and yarn, making the fabric skin-friendly, freely breathable, excellent in elasticity, not out of gear, durable in wearing, giving users an excellent wearing experience, and endowing the product with functions;

[0071] Second, the fabric of the present disclosure also has far-infrared performance, stores the heat emitted by the human body, and transfers it back to the human body in the form of radiant heat to achieve a warming effect, with a heat preservation rate of 34.1%;

[0072] Third, the fabric of the present disclosure also has antistatic properties.

[0073] It can be understood that the above embodiments are merely exemplary embodiments adopted to illustrate the principle of the present disclosure. However, the present disclosure is not limited thereto. For those of ordinary skill in the art, various modifications and improvements can be made without departing from the spirit and essence of the present disclosure, and these modifications and improvements are also regarded as the protection scope of the present disclosure.

Claims

1. A liquid-dyed, ultra-thick, warm-keeping integrated fabric, characterized in that: The liquid-dyed, ultra-thick, warm-keeping integrated fabric is woven by a double-sided large circular machine and is woven by a first yarn, a second yarn, a third yarn, and a fourth yarn according to a two-way circular weaving method; wherein, The first route of the two-way circular knitting method uses the first yarn and the second yarn, and the second route uses the third yarn and the fourth yarn; The first yarn and the third yarn are 75D-200DDTY liquid polyester or nylon; The second yarn and the fourth yarn are E70-E200D liquid spandex.

2. The liquid-dyed ultra-thick warm-keeping integrated fabric according to claim 1, characterized in that: The 75D-200DDTY stock polyester or nylon is a 75D-200D coarse-count polyester or nylon that has been subjected to a coloring treatment.

3. The liquid-dyed ultra-thick warm-keeping integrated fabric according to claim 1, characterized in that: E70-E200D liquid spandex is a coarse-count spandex of 75D-200D that has been dyed.

4. A weaving process for preparing the liquid-dyed ultra-thick warm-keeping integrated fabric as claimed in any one of claims 1 to 3, characterized in that: The weaving process comprises: Obtain a first yarn and a third yarn of 75D-200DDTY stock polyester or nylon; Obtaining a second yarn and a fourth yarn of E70-E200D liquid spandex; The first yarn and the second yarn are used as the first raw material, the third yarn and the fourth yarn are used as the second raw material, and the two raw materials are woven using a double-sided circular knitting machine to form a liquid-dyed ultra-thick warm-keeping integrated fabric.

5. The weaving process according to claim 4, characterized in that: The double-sided large circular machine adopts a 20G-32G double-sided large circular machine.

6. The weaving process according to claim 4, characterized in that: The number of needles of the fabric is 34, the width of the fabric is 6.5 cm, and the weight of the fabric is 100G.

7. The weaving process according to claim 4, characterized in that: The method of obtaining the first yarn and the third yarn of 75D-200DDTY liquid polyester comprises: Drying PET chips of 75D-200D specifications, and evenly mixing the masterbatch with the dried PET chips to obtain a mixed material; The mixed material is put into a screw extruder, heated and melted to obtain a molten material; The molten material is extruded from the fine holes of the spinneret to form a thin stream, and is cooled and solidified into a filament in the spinning tunnel; The yarns are stretched in a single stage or multiple stages on a stretching machine, and the stretched yarns are heated to form 75D-200DDTY stock polyester.

8. The weaving process according to claim 4, characterized in that: The method of obtaining the first yarn and the third yarn of 75D-200DDTY liquid nylon comprises: Pre-treating the raw material for producing DTY nylon, and evenly mixing the masterbatch and the pre-treated raw material to obtain a mixed material; The mixed material is put into a polymerization reaction kettle, and a polymerization reaction is carried out under the action of a high temperature, a catalyst and an auxiliary agent to form a nylon polymer and gradually condense into nylon particles; The nylon particles are heated to high temperature and melted, and then extruded and stretched into initial fibers through a spinning machine; The initial fibers are low-drawn and high-temperature heat-set, and the set fibers are preheated to obtain 75D-200DDTY stock nylon.

9. The weaving process according to claim 4, characterized in that: The method of obtaining the second yarn and the fourth yarn of E70-E200D liquid spandex comprises: Polytetramethylene ether glycol and diphenylmethane diisocyanate are used as main raw materials and pretreated, polytetramethylene ether glycol and diphenylmethane diisocyanate are mixed, and prepolymerized under certain temperature conditions to generate a prepolymer containing isocyanate groups (-NCO) at both ends of the molecule; The prepolymer is fully dissolved to obtain a prepolymer solution, the prepolymer solution is transferred to a polymerization reactor, stirred evenly, and a mixed amine DMAC solution of a chain extender and a terminator is added in a controlled manner to perform chain extension and chain termination reactions to obtain a polymer solution; In the process of continuously transferring the polymer solution continuously generated in the polymerization reactor into the stirring tank, quantitatively adding the pre-prepared masterbatch solution into the stirring tank, fully stirring and mixing, so that the masterbatch is evenly dispersed in the polymer solution, and the spandex spinning stock solution is obtained; The spandex spinning stock solution is woven into E70-E200D stock spandex by adopting a spinning forming process.

10. A liquid-dyed, ultra-thick, warm-keeping integrated leggings, characterized in that: The leggings are formed from the fabric described in any one of claims 1-3.

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