Manufacturing method of double-sided looped pile cleaning cloth

Abstract

The invention discloses a manufacturing method of a double-sided terry cleaning cloth, which comprises a first terry layer, a second terry layer, a middle substrate layer and binding yarns, the first terry layer and the second terry layer respectively adopt PET silver-plated filaments and bamboo fiber filaments, the binding yarns synchronously fix double-sided terry on two sides of the middle substrate layer, and weaving adopts a twelve-needle high-density warp knitting machine, the method specifically comprises the processes of double-comb-section synchronous looping, binding yarn dynamic fixing and ground yarn transverse movement positioning. A double-sided different-material terry structure is adopted, the PET silver-plated wire terry surface can remove stubborn oil stains, is free of scratches, is suitable for utensils such as plastics, ceramics and non-stick pans, has metal detergency but keeps flexibility, and replaces a traditional steel wire ball; the bamboo fiber terry surface has antibacterial, water-absorbing, oil-free and peculiar smell-inhibiting effects, so that bacterium breeding is reduced, and the peculiar smell problem of traditional cleaning cloth is avoided; the terylene substrate is combined with the binding structure, so that firm combination of the double-sided looped piles and the ground yarns is ensured, and the overall wear resistance of the cleaning cloth is improved.

Description

Technical Field

[0001] The present invention relates to the field of textile technology, and more particularly to a method for manufacturing a double-sided terry cleaning cloth. Background Art

[0002] There are many tools for washing dishes, and cleaning cloths are the most common. Previously, steel wool was popular for washing dishes and pots. While it has strong cleaning power, it can easily scratch utensils (such as non-stick pans and ceramic tableware), rust, and breed bacteria. Furthermore, steel wool can cause serious skin damage during use. Nowadays, steel wool is rarely used, and soft cloths and sponges are more popular.

[0003] However, the texture of cloth or sponge is relatively soft. Although it will not damage pots and pans, and it is highly absorbent, which helps pots and pans dry quickly after washing, the cloth or sponge is too soft to easily remove stubborn grease (such as rice crust, dried food residue, etc.) stuck on the bowls, greatly reducing its practicality. Traditional single-sided terry dishcloths have a single function and cannot meet the needs of both cleaning and water absorption. Double-sided terry technology often uses the same material, which cannot achieve differentiated functions on both sides. To meet consumer needs, there is an urgent need for a product that can simultaneously meet the complex functions of strong cleaning, no damage to the surface, water absorption and antibacterial, durable and easy to wash. Summary of the Invention

[0004] The invention provides a method for manufacturing a double-sided terry cleaning cloth, which not only has the softness of an ordinary dishwashing cloth but also has the strong decontamination effect of a steel wool.

[0005] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a method for manufacturing a double-sided terry cleaning cloth, comprising a first terry layer, a second terry layer, an intermediate substrate layer and a binding yarn, the first terry layer and the second terry layer respectively use PET silver-plated wire and bamboo fiber filament, the binding yarn synchronously fixes the double-sided terry on both sides of the intermediate substrate layer, and the weaving adopts a twelve-needle high-density warp knitting machine, specifically including double-comb section synchronous loop formation, dynamic fixation of the binding yarn and lateral positioning process of the bottom yarn.

[0006] Furthermore, in the double-comb section synchronous loop forming process, the front and rear comb sections control the bamboo fiber filaments and the PET silver-coated yarn respectively, and the loops are cast off by the needle plate to form double-sided terry loops. The let-off ratio of the front-combed bamboo fiber and the rear-combed PET silver-coated yarn is 1.05-1.08:1, the loop forming phase difference is 0.5-0.7 ms, the sinker stroke difference is 0.5-1 mm, and the aperture of the bamboo fiber guide needle is 12-15% larger than that of the PET silver-coated yarn side.

[0007] Furthermore, in the dynamic fixing process of the bundling yarn, the double-sided terry is firmly combined with the bottom yarn through 200D polyester filament bundling yarn, and the latch needle moves up and down to crochet and bundle the bottom yarn and the two-sided terry to ensure structural stability. The frequency of the latch needle's up and down movement is synchronized with the main loop forming cycle. Crochet once every two horizontal rows, and the crocheting depth is 50% of the thickness of the hooked bottom yarn + the roots of the terry on both sides.

[0008] Furthermore, in the bottom yarn transverse movement positioning process, a stable middle substrate layer is formed by the transverse movement of the tube needle to carry the double-sided terry loops. The bottom yarn is combed through the middle of the warp knitting machine. The bottom yarn uses 300D polyester filament as the substrate. The middle combing section tube needle moves horizontally left and right to form a mesh substrate structure with the bundled yarn. The transverse movement speed of the tube needle is synchronized with the main loop formation.

[0009] Furthermore, the preparation process of PET silver-plated wire includes the following steps:

[0010] S1. Plasma cleaning of polyester film: A biaxially oriented polyester film was selected and plasma cleaning was performed to remove organic residues on the surface;

[0011] S2. Vacuum silver plating: Using gradient coating technology, magnetron sputtering deposits chromium, silver, and diamond-like carbon layers in sequence. A 5nm chromium layer is sputtered on the bottom layer to enhance bonding strength; the middle layer is a pure silver layer with a thickness of 50-80nm; and a protective layer of 2nm diamond-like carbon film is used to prevent silver oxidation. The process parameters used for silver plating are a vacuum of 5×10-3Pa and a substrate temperature of 80°C. The low temperature prevents film deformation.

[0012] S3. Freeze embrittlement treatment: Liquid nitrogen cryogenic treatment is used to embrittle the film material. The silver-plated polyester film is immersed in liquid nitrogen and rapidly frozen to embrittle the polymer chain segments. The liquid nitrogen temperature is -196±5℃ and the freezing time is ≥30 seconds. The crystallinity is increased to more than 60% (about 40% of the original film), and the hardness is increased by 30% (Shore D hardness ≥85).

[0013] S4. Micron-level slitting in a low-temperature environment: slitting is performed in a low-temperature environment of -50°C to -80°C.

[0014] Furthermore, the slitting temperature is -60°C ± 2°C.

[0015] Furthermore, the loop height is 7±0.5 mm.

[0016] In summary, the present invention adopts a double-sided terry structure with different materials, which has the advantages of strong detergency, good hygiene and durability, and has the following beneficial effects:

[0017] 1. The silver-plated PET terry surface can remove stubborn oil stains (such as rice crust) without scratches. It is suitable for plastic, ceramic, non-stick pans and other utensils. It has metal decontamination power but maintains flexibility, replacing traditional steel wool.

[0018] 2. The bamboo fiber terry surface is antibacterial, water-absorbent and oil-free, which can inhibit odor, reduce bacterial growth, and avoid the odor problem of traditional rags;

[0019] 3. The polyester backing combined with the bundling structure ensures a firm bond between the double-sided terry and the bottom yarn, avoids the use of adhesives (environmentally friendly and washable), and improves the overall tensile and wear resistance of the cleaning cloth. DETAILED DESCRIPTION

[0020] The following is a further detailed description of a specific embodiment of a method for manufacturing a double-sided terry cleaning cloth of the present invention.

[0021] A method for manufacturing a double-sided terry cleaning cloth comprises a first terry layer, a second terry layer, an intermediate substrate layer and a binding yarn. The first terry layer and the second terry layer are made of PET silver-plated wire and bamboo fiber filaments, respectively. The binding yarn synchronously fixes the double-sided terry to both sides of the intermediate substrate layer. The weaving is carried out using a twelve-needle high-density warp knitting machine, specifically including double-comb section synchronous loop formation, dynamic fixing of the binding yarn and transverse positioning of the bottom yarn.

[0022] The cleaning cloth is woven from four yarns: the first yarn is a silver-plated PET yarn for the first terry layer (PET film vacuum-silvered and cut into 300D filaments); the second yarn is a 300D bamboo fiber yarn for the second terry layer; the third yarn is a base yarn (300D polyester filament); and the fourth yarn is a binding yarn (200D polyester filament). The first and second yarns are looped together and then bound to both sides of the base yarn by the binding yarn, forming a double-sided, heterogeneous terry cleaning cloth that combines strong detergency with moisture absorption and softness.

[0023] Preferably, in the double-comb section synchronous loop forming process, the front and rear comb sections respectively control the bamboo fiber filaments and the PET silver-plated yarn, and double-sided terry loops are formed by needle plate undocking. The warp feed ratio of the front-combed bamboo fiber and the rear-combed PET silver-plated yarn is 1.05-1.08:1, the loop forming phase difference is 0.5-0.7ms, the sinker stroke difference is 0.5-1mm", and the aperture of the bamboo fiber yarn guide needle is 12-15% larger than that of the PET silver-plated yarn side. The elastic difference between the PET silver-plated yarn and the bamboo fiber is compensated by delayed / advanced yarn feeding to achieve high consistency of the terry loops.

[0024] Preferably, in the dynamic fixing process of the bundling yarn, the double-sided terry is firmly combined with the bottom yarn by using 200D polyester filament bundling yarn, and the latch needle moves up and down to crochet and bundle the bottom yarn and the two-sided terry to ensure structural stability. The frequency of the latch needle's up and down movement is synchronized with the main looping cycle. It crochets once every two horizontal rows, and the crochet depth is 50% of the thickness of the hooked bottom yarn + the roots of the terry on both sides. The latch needle crochets once every two horizontal rows, saving 20% of the yarn usage. At the lateral turning point, the bundling yarn is wrapped around 2 additional turns to reinforce the interweaving point. The height of the terry is matched with the crocheting depth of the bundling yarn (7mm terry requires a 3.5mm crocheting depth) to ensure that it is not easy to pull out the yarn during washing.

[0025] In this embodiment, preferably, in the bottom yarn lateral positioning process, a tube needle moves horizontally to form a stable intermediate backing layer to support the double-faced terry loops. The warp knitting machine intersects the bottom yarn, which uses 300D polyester filament as the backing. The tube needles in the middle comb section move horizontally to form a mesh backing structure with the bundled yarn. The tube needle lateral movement speed is synchronized with the main loop formation. The tube needle is closed-loop controlled with a positioning accuracy of ±0.05mm to prevent deformation of the backing.

[0026] In this embodiment, the preparation process of the PET silver-plated wire preferably includes the following steps:

[0027] S1. Plasma cleaning of polyester film: Use plasma cleaning to remove organic residues from the surface of biaxially oriented polyester film. Plasma cleaning (Ar / O2 mixed gas, 300W power, 5 minutes) replaces traditional chemical cleaning to remove organic residues and improve silver plating adhesion.

[0028] S2. Vacuum Silver Plating: Using a gradient coating technique, magnetron sputtering sequentially deposits chromium, silver, and diamond-like carbon layers. A 5nm chromium layer is sputtered on the bottom layer to enhance bonding; a 50-80nm thick pure silver layer is used as the intermediate layer; and a 2nm diamond-like carbon film is used as the protective layer to prevent silver oxidation. The silver plating process parameters include a vacuum of 5×10-3 Pa and a substrate temperature of 80°C to prevent film deformation. S3. Freeze Embrittlement Treatment: Liquid nitrogen cryogenic treatment is used to embrittle the film. The silver-coated polyester film is immersed in liquid nitrogen and rapidly frozen to embrittle the polymer chains. The liquid nitrogen temperature is -196±5°C, and the freezing time is ≥30 seconds. The glass transition temperature (Tg) of ordinary PET film is approximately 70-80°C. However, after cryogenic treatment (liquid nitrogen -196°C), the crystallinity is enhanced, and the Tg can be reduced to -40°C to -50°C. The slitting temperature must be below the Tg to ensure brittle fracture (rather than ductile tearing) and reduce burrs. The crystallinity is increased to more than 60% (about 40% of the original film), and the hardness is increased by 30% (Shore D hardness ≥ 85).

[0029] S4. Micron-level slitting in a low-temperature environment: Slitting is carried out in a low-temperature environment of -50℃ to -80℃. When performing micron-level slitting in a low-temperature environment, temperature control is crucial, which directly affects the cutting quality and efficiency of the silver-coated PET wire. The slitting temperature range is controlled between -50℃ and -80℃, with a lower limit of -50℃ to ensure that the PET film remains brittle (below the glass transition temperature Tg) to avoid ductile deformation during cutting; the upper limit is -80℃ to prevent excessive brittleness of the material due to excessive temperature (which may cause microcracks).

[0030] In this embodiment, the slitting temperature is preferably -60°C ± 2°C. -60°C is the optimal temperature for micron-scale slitting of PET silver-plated wires, which avoids heat conduction affecting the brittleness of PET and can simultaneously meet the requirements of good cut flatness (burrs ≤ 2μm) and high silver layer retention rate (≥97%).

[0031] Preferably, in this embodiment, the height of the terry loop is 7±0.5mm. The 7mm terry loop height can form sufficient elastic support to allow the PET silver-plated wire to fully contact the stains and enhance the friction effect. The 7mm terry loop is fixed by polyester bundling yarn to form a stable "spring-like support" in the warp knitted structure. After 5,000 friction tests (ASTM D4966), the height retention rate is ≥90% (5mm terry loop is only 75%). And the softness and cushioning properties of the 7mm terry loop are better than those of the short terry loop, which reduces hand fatigue when wiping tableware. Experimental data show that the removal efficiency of the 7mm terry loop for stubborn grease (such as rice crust) is 30% higher than that of the 5mm terry loop (GB / T22799-2019 standard test).

[0032] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for making a double-sided terry cleaning cloth, characterized in that: It includes a first terry layer, a second terry layer, an intermediate base layer and binding yarn. The first terry layer and the second terry layer are made of PET silver-plated wire and bamboo fiber filament respectively. The binding yarn synchronously fixes the double-sided terry on both sides of the intermediate base layer. The weaving adopts a twelve-needle high-density warp knitting machine, which specifically includes double-comb section synchronous loop formation, dynamic fixation of binding yarn and lateral positioning process of bottom yarn.

2. The method for making a double-sided terry cleaning cloth according to claim 1, characterized in that: In the double-comb section synchronous loop forming process, the front and rear comb sections control the bamboo fiber filaments and the PET silver-coated yarn respectively, and the loops are cast off by the needle block to form double-sided terry loops. The let-off ratio of the front-comb bamboo fiber and the rear-comb PET silver-coated yarn is 1.05-1.08:1, the loop formation phase difference is 0.5-0.7ms, the sinker stroke difference is 0.5-1mm, and the aperture of the bamboo fiber guide needle is 12-15% larger than that of the PET silver-coated yarn side.

3. The method for making a double-sided terry cleaning cloth according to claim 1, characterized in that: In the dynamic fixing process of the bundling yarn, the double-sided terry is firmly combined with the bottom yarn through the 200D polyester filament bundling yarn, and the latch needle moves up and down to crochet and bundle the bottom yarn and the two-sided terry to ensure structural stability. The frequency of the latch needle's up and down movement is synchronized with the main loop forming cycle. Crochet is performed once every two horizontal rows, and the crocheting depth is 50% of the thickness of the hooked bottom yarn + the roots of the terry on both sides.

4. The method for making a double-sided terry cleaning cloth according to claim 1, characterized in that: In the bottom yarn transverse movement positioning process, a stable middle substrate layer is formed by the transverse movement of the tube needle to carry the double-sided terry loops. The bottom yarn is passed through the middle comb of the warp knitting machine. The bottom yarn uses 300D polyester filament as the substrate. The middle combing section tube needle moves horizontally left and right to form a mesh substrate structure with the bundled yarn. The transverse movement speed of the tube needle is synchronized with the main loop formation.

5. The method for making a double-sided terry cleaning cloth according to claim 1, characterized in that: The preparation process of PET silver-plated wire includes the following steps: S1. Plasma cleaning of polyester film: A biaxially oriented polyester film was selected and plasma cleaning was performed to remove organic residues on the surface; S2. Vacuum silver plating: Using gradient coating technology, magnetron sputtering deposits chromium, silver, and diamond-like carbon layers in sequence. A 5nm chromium layer is sputtered on the bottom layer to enhance bonding strength; the middle layer is a pure silver layer with a thickness of 50-80nm; and a protective layer of 2nm diamond-like carbon film is used to prevent silver oxidation. The process parameters used for silver plating are a vacuum of 5×10-3Pa and a substrate temperature of 80°C. The low temperature prevents film deformation. S3. Freeze-Debrittle Treatment: Liquid nitrogen cryogenic treatment is used to embrittle the film. The silver-coated polyester film is immersed in liquid nitrogen and rapidly frozen to embrittle the polymer segments. The liquid nitrogen temperature is -196±5°C and the freezing time is ≥30 seconds. The crystallinity is increased to over 60% (from approximately 40% of the original film), and the hardness is increased by 30% (Shore D hardness ≥85). S4. Micron-level slitting in a low-temperature environment: slitting is performed in a low-temperature environment of -50°C to -80°C.

6. The method according to claim 5, wherein: The cutting temperature is -60℃±2℃.

7. The method according to claim 1, wherein: The loop height is 7±0.5 mm.