Inflatable leaning ball structure for fully-formed knitted ship and preparation method of inflatable leaning ball structure

Abstract

The invention discloses an inflatable leaning ball structure for a fully-formed knitted ship and a preparation method of the inflatable leaning ball structure, and belongs to the field of industrial protective textiles. The ball leaning structure comprises a bottom opening area, a bottom radian primary structure area, a bottom shaping needle adjusting area, a middle wear-resisting area, a top shaping needle adjusting area, a top radian primary structure area and a neck opening area which are sequentially arranged from bottom to top, all the areas are sequentially and seamlessly connected, and an air chamber of the ball leaning structure is formed through integral forming and weaving. The leaning ball structure is integrally formed through a full-forming weaving process, the number of joints is reduced, the problem of stress concentration at the joints is solved, the overall strength of the fabric structure is higher, impact force generated when a ship stops can be more effectively borne, durability of the leaning ball is improved, the service life is prolonged, meanwhile, the corrosion resistance is higher, and the service life of the leaning ball is prolonged. And the puncture resistance is better, so that the replacement frequency can be reduced, and the use cost is reduced.

Description

Technical Field

[0001] This invention relates to a fully formed knitted marine inflatable ball structure and its preparation method, belonging to the field of industrial protective textiles. Background Technology

[0002] Inflatable rubber fenders are a type of inflatable fender device. Their basic structure consists of an outer rubber layer, a synthetic cord-reinforced rubber layer, and an inner rubber layer, filled with compressed air. Utilizing the plasticity of compressed air and the high pressure-bearing capacity of the rubber airbag as a buffer, they absorb the enormous impact energy generated when a ship berths, effectively protecting the ship's hull, dock, or pier structure. Compared to commonly used compressed solid rubber fenders, they are lightweight, flexible, and safe, while also possessing special shock and vibration absorption capabilities. Therefore, they have become an essential protective facility for various large vessels during berthing, and are particularly suitable for flexible berthing systems such as large oil tankers, docks, pontoons, dry docks, and offshore drilling platforms.

[0003] However, existing inflatable rubber balls still have significant drawbacks. Because they are primarily made of rubber, prolonged exposure to air, sunlight, or seawater can easily lead to hardening, cracking, fading, and other aging problems, resulting in a typically short lifespan. Furthermore, they are easily scratched by sharp objects, and repairs are difficult and costly, often requiring replacement and increasing overall usage costs. Summary of the Invention

[0004] To address the problems of existing marine ballast balls, which are made of rubber and therefore prone to aging, short service life, poor puncture resistance, and easy tearing, thus increasing usage costs, this invention provides a fully formed knitted marine inflatable ballast ball structure and its preparation method. The technical solution is as follows: A fully formed knitted marine inflatable ball support structure, the ball support structure comprising: The bottom opening area, bottom arc initial structure area, bottom shaping and needle adjustment area, middle wear-resistant area, top shaping and needle adjustment area, top arc initial structure area, and neck opening area are arranged sequentially from bottom to top. The bottom opening area, the bottom arc initial structure area, the bottom shaping and needle adjustment area, the middle wear-resistant area, the top shaping and needle adjustment area, the top arc initial structure area, and the neck opening area are seamlessly connected in sequence and formed by one-piece molding to create the outer contour of the ball-shaped structure.

[0005] Furthermore, the bottom opening area, the bottom preliminary structure area, the top preliminary structure area, and the neck opening area are all woven with the first yarn, while the bottom shaping and adjusting needle area, the middle abrasion-resistant area, and the top shaping and adjusting needle area are all woven with the second yarn.

[0006] Furthermore, the tensile strength at break of the second yarn is higher than that of the first yarn.

[0007] Furthermore, the first yarn and the second yarn are made of ultra-high molecular weight polyethylene yarn or high-strength polyester yarn.

[0008] Furthermore, the bottom arc initial shaping area is symmetrical to the top arc initial shaping area, and the bottom shaping needle adjustment area is symmetrical to the top shaping needle adjustment area.

[0009] Furthermore, inside the ball-supporting structure, at the location of the middle wear-resistant zone, there is also an integrally woven fabric partition area, which divides the inner cavity of the ball-supporting structure into two air chambers, left and right, through the fabric partition area.

[0010] Furthermore, the bottom shaping and adjusting needle area can adjust the roundness of the ball support structure and the cylinder diameter by adding needles; the middle wear-resistant area can increase the length of the ball support structure by adding knitting cycles.

[0011] A method for preparing a fully formed knitted marine inflatable ball bearing structure, the method comprising: Step 1: Knitting the bottom opening area. First, use the front and back needle bed stitches to arrange the needles, knitting one stitch every other stitch on one side to complete the base knitting of the opening part. Then, use the four-stitch knitting method on both sides to complete the base knitting of the closed part. Next, use the front and back needle bed stitches to knit the air layer structure, continuing the base knitting in the middle. After 2 rows, switch to full stitch knitting and knit normally. Knit plain on both sides to form the bottom opening state and tubular structure of the ball-shaped structure. Step 2: Knit the initial structure of the bottom arc. Partial knitting is used, in which the front and back needle beds are fully knitted, and the needles on both sides of the front and back needle beds are partially stopped along each row, so that there are still old loops on both sides, while the middle part is knitted with new loops, thus completing the initial structure of the bottom arc of the ball-shaped structure. Step 3: Knitting the bottom shaping and adjusting needle area. By increasing needles, insert the partial knitting into the cylindrical knitting area according to a certain proportion, ensuring that the bottom arc is first rapid and then slow, and the stopping edge is completed by gathering the loops to connect the stopping part of the fabric with the plain weave fabric, thus completing the knitting of the bottom arc of the ball structure. Step 4: Knitting the middle abrasion-resistant zone. The front and rear needle beds adopt an air layer structure knitting method using a needle-to-needle approach, that is, the front and rear needle beds adopt cylindrical knitting to form the main area of ​​the ball-shaped structure. Step 5: Knit the top shaping and adjusting area. Use partial knitting and insert the partial knitting into the cylindrical knitting area according to a certain proportion to ensure that the top arc of this area is initially gentle and then becomes rapid. Step 6: Knit the initial arc area at the top. The knitting method in the middle of the front and back needle beds remains unchanged. On both sides of the front and back needle beds, knit row by row while decreasing stitches to perform flat binding and locking, thus completing the top knitting of the ball-shaped structure. Step 7: Knit the neck opening area using a cylindrical knitting method, reducing the number of stitches. Knit all the stitches on the front and back needle beds into circles to achieve the required neck height. Finally, bind off the stitches to finish the knitting.

[0012] Furthermore, in step 4, during the cylindrical knitting process of the front and rear needle beds, a dense double rib structure is knitted simultaneously by performing a transverse barrier structure knitting in the middle area of ​​the front and rear needle beds. The dense rib structure forms a fabric partition area, so that the ball-shaped structure physically separates the left and right air chambers.

[0013] Furthermore, in steps 3 and 5, the partial weaving is a cycle of 6 rows, and partial weaving can be gradually inserted every 2, 4, and 6 rows.

[0014] The beneficial effects of this invention are: By using a fully-integrated weaving process to mold the ball structure in one piece, the number of seams is reduced, thereby reducing stress concentration at the seams. This results in higher overall strength of the fabric structure, enabling it to withstand the impact of ships docking more effectively, improving the ball's durability and extending its service life. At the same time, it has stronger corrosion resistance and better puncture resistance, thus reducing the frequency of replacement and lowering operating costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is an overall schematic diagram of the ball-supporting structure according to Embodiment 1 of the present invention; Figure 2 This is a flowchart of the method for preparing the inflatable ball structure provided in Embodiment 2 of the present invention; Figure 3 This is a schematic diagram of the weaving of the bottom opening area in Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of the weaving of the bottom arc initial structure area in Embodiment 2 of the present invention; Figure 5 This is a schematic diagram of the bottom shaping and needle adjustment area knitting according to Embodiment 2 of the present invention; Figure 6 This is a schematic diagram of the weaving of the wear-resistant zone in the middle of the spherical and cylindrical shapes near the ball in Embodiment 2 of the present invention; Figure 7 This is a schematic diagram of the tandem ball-supporting middle wear-resistant zone weaving in Embodiment 2 of the present invention; Among them: 1- Bottom opening area; 2- Bottom curvature preliminary area; 3- Bottom shaping and adjusting needle area; 4- Middle wear-resistant area; 5- Top shaping and adjusting needle area; 6- Top curvature preliminary area; 7- Neck opening area; 8- Series ball-supporting middle wear-resistant area. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0018] Example 1 This embodiment provides a fully formed knitted marine inflatable ball support structure. See [link / reference] Figure 1 (a, b), the ball-holding structure includes: The bottom opening area 1, bottom curved initial structure area 2, bottom shaping and needle adjustment area 3, middle wear-resistant area 4, top shaping and needle adjustment area 5, top curved initial structure area 6, and neck opening area 7 are arranged sequentially from bottom to top. These areas are seamlessly joined together and feature an integrally woven outer ball-shaped structure. A matching airbag is then placed inside this outer contour. When inflated, the airbag forms a complete ball-shaped structure. This invention, through the use of a woven, integrally woven ball-shaped structure, achieves higher overall strength and protects the internal airbag, effectively preventing scratches, punctures, or other damage. This enhances the overall durability of the airbag, extends its service life, and reduces replacement costs.

[0019] Furthermore, the bottom opening area 1, bottom preliminary structure area 2, top preliminary structure area 6, and neck opening area 7 are all woven from the first yarn A, while the shaping and adjusting needle area 3, the middle abrasion-resistant area 4, and the top shaping and adjusting needle area 5 are all woven from the second yarn B. The tensile strength at break of the second yarn B is higher than that of the first yarn A. Since the central area of ​​the inflatable ball-support structure is the main external force-bearing area during actual use, selecting yarns with different tensile strengths at break not only optimizes the manufacturing cost but also ensures the overall durability of the ball-support structure by guaranteeing the strength of the main external force-bearing area in the center.

[0020] Preferably, both the first yarn A and the second yarn B can be made of ultra-high molecular weight polyethylene yarn or high-strength polyester. The ultra-high molecular weight polyethylene yarn has a specification of 2000D twisted / untwisted and 350D×4P, and the high-strength polyester has a specification of 1800D (Hailide). Ordinary polyester can also be used, with specifications of 900D×2P, 1100D+400D+400D, or 600D×3P.

[0021] Furthermore, the bottom arc initial shaping area 2 and the top arc initial shaping area 6 are symmetrical to each other, and the bottom shaping needle adjustment area 3 and the top shaping needle adjustment area 5 are symmetrical to each other.

[0022] Furthermore, regarding the interior of the spherical structure, see... Figure 1 As shown in (c), an integrally woven fabric partition area 8 is also provided at the middle wear-resistant zone 4. The fabric partition area 8 divides the inner cavity of the ball-support structure into two air chambers, left and right. This ball-support structure is a series ball-support structure. With the design of two air chambers, two matching airbags can be built in. In this way, even if one airbag is damaged during use, the other airbag can still play an anti-collision function, ensuring safety during use.

[0023] Furthermore, the bottom shaping and adjusting needle area 3 can adjust the roundness of the ball support structure and the size of the cylinder diameter by adding needles; the middle abrasion-resistant area 4 can increase the length of the ball support structure by adding knitting cycles.

[0024] The beneficial effects of the ball-support structure in this embodiment are as follows: (1) The whole-body forming process is adopted to reduce the number of seams, thereby reducing the stress concentration problem at the seams, making the overall strength of the fabric structure higher, and more effectively able to withstand the impact force when the ship docks, thus improving the durability of the ball. (2) Convenient to store. Its built-in airbag can be inflated and deflated. After deflation, it can be folded to save space. Compared with traditional rubber ball, it is lighter and greatly reduces the load on the hull. (3) The shape can be designed. In addition to the conventional cylindrical shape, spherical, ring and other shapes can also be designed to create innovative shapes; (4) Patterns and weave structures can be designed. In addition to the conventional plain stitch structure, weave structures such as tuck, float, and jacquard can also be designed. In addition to increasing mechanical properties, weave logos or other patterns can also be designed. (5) Ultra-high molecular weight polyethylene fiber or high-strength polyester fiber can be used for weaving. These materials have excellent resistance to seawater corrosion and can be used in the seawater environment for a long time without being easily damaged. At the same time, they have high mechanical strength and wear resistance and can resist friction and collision between ships and dock facilities.

[0025] Example 2 This embodiment provides a method for preparing a fully formed knitted marine inflatable ball structure. (See [link to documentation]). Figure 2 The method includes: A method for preparing a fully formed knitted marine inflatable ball bearing structure, the method comprising: Step 1, Knitting the bottom opening area 1: First, use the needle bed arrangement method with alternating stitches (one stitch every other stitch) on one side. See [link / reference]. Figure 3 As shown in the first row, the bottom opening area is now complete with the initial knitting. See [link / reference]. Figure 3 As shown in the other rows, the double-sided knitting method of four plain stitches is used on both sides to complete the bottom part of the closed part; then the air layer structure is knitted by front and back needle beds, and the bottom knitting continues in the middle. After 2 rows, switch to full needle plain stitch for normal knitting, and knit plain on both sides to form the bottom opening state of the ball structure and the tubular structure. Step 2: Weaving the initial bottom arc section 2. This involves partially weaving the bottom opening area to achieve the bottom arc shape of the ball-shaped structure. (See attached image) Figure 4 As shown, the partial knitting is in a full stitch knitting state on both the front and back needle beds. The needles on both sides of the front and back needle beds are stopped in sections, so that there are still old loops on both sides, while the middle part is knitted with new loops to complete the initial construction of the bottom arc of the ball structure. Step 3: Knit the bottom shaping and adjusting stitch area 3, see below. Figure 5 As shown, based on the initial arc area 2 at the bottom, the roundness of the arc and the size of the cylinder diameter of the ball-support structure are controlled by adding stitches according to the outline of the ball-support structure. Local knitting is inserted into the cylinder knitting area at a certain proportion. Specifically, this proportion of local knitting is a cycle of 6 rows, and local knitting can be gradually inserted every 2, 4, and 6 rows. This ensures that the bottom arc is initially sharp and then gradually decreases, and the stitches stop at the edge using a tucking method to connect the stitched part of the fabric with the plain weave fabric, thus completing the bottom arc knitting part of the ball-support structure. Step 4, weaving the middle abrasion-resistant zone 4, see below. Figure 6 As shown, the front and rear needle beds adopt an air layer weaving method in a needle-oriented manner, that is, the front and rear needle beds adopt cylindrical weaving to form the main body of the ball-shaped structure. Step 5: Knitting the top shaping and adjusting area 5. The knitting structure in this step is symmetrical to that in Step 3. Based on the outline of the ball structure, on the basis of the middle wear-resistant area 4, local knitting is also inserted into the cylindrical knitting area according to a certain proportion. This certain proportion of local knitting is a cycle of 6 rows. Local knitting can be gradually inserted every 6 rows, 4 rows, and 2 rows to ensure that the top arc of this area is slow at first and then fast. Step 6: Knit the initial structure of the top arc. The knitting structure in this step is symmetrical to that in Step 2. The knitting method in the middle of the front and back needle beds remains unchanged. The knitting and undoing method is used on both sides of the front and back needle beds to perform flat binding and locking, thus completing the top knitting of the ball-shaped structure. Step 7: Knit the neck opening area using the cylindrical knitting method, reducing the number of stitches (i.e., reducing the cylinder diameter). Knit all the stitches on the front and back needle beds into circles to achieve the required neck height. Finally, bind off the stitches to finish the knitting.

[0026] The ball-shaped structure prepared by the above method has a single air chamber ( Figure 1 The one-piece molding and weaving method of the ball-supporting structure in (a) and (b) is for Figure 1 The tandem ball-supporting structure in section c differs from the weaving method described above in that, in step 4, the fabric blocking area 8 is woven synchronously. For details, see [link to details]. Figure 7 As shown, in step 4, during the knitting process of the front and rear needle beds, a dense double rib structure is knitted simultaneously by knitting a transverse barrier structure in the middle area of ​​the front and rear needle beds. The dense rib structure forms a fabric partition area, so that the ball-shaped structure physically separates the left and right air chambers.

[0027] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A fully-fashioned, knitted, marine fender ball structure, characterized by, The ball structure comprises: The bottom opening area, the bottom arc initial structure area, the bottom shaping needle adjusting area, the middle wear-resistant area, the top shaping needle adjusting area, the top arc initial structure area and the neck opening area are sequentially and seamlessly connected and formed as an integral knitted contour of the ball structure.

2. A fully formed knitted marine fender ball structure according to claim 1, wherein, The bottom opening area, the bottom initial structure area, the top initial structure area and the neck opening area are knitted by the first yarn, and the bottom shaping needle adjusting area, the middle wear-resistant area and the top shaping needle adjusting area are knitted by the second yarn.

3. A fully formed knitted marine fender ball structure according to claim 2, wherein, The breaking tensile strength of the second yarn is higher than that of the first yarn.

4. A fully formed knitted marine fender ball structure according to claim 3, wherein, The first yarn and the second yarn are ultra-high molecular weight polyethylene yarns or high-strength polyester yarns.

5. A fully formed knitted marine fender ball structure according to claim 1, wherein, The bottom arc initial structure area and the top arc initial structure area are symmetrical to each other, and the bottom shaping needle adjusting area and the top shaping needle adjusting area are symmetrical to each other.

6. A fully formed knitted marine fender ball structure according to claim 1, wherein, In the ball structure, a fabric partition area is further arranged at the position of the middle wear-resistant area, and the inner cavity of the ball structure is divided into left and right air chambers by the fabric partition area.

7. A fully formed knitted marine fender ball structure according to claim 1, wherein, The bottom shaping needle adjusting area can adjust the circular arc degree and the barrel diameter of the ball structure by adding needles, and the middle wear-resistant area can increase the length of the ball structure by increasing the knitting cycle.

8. A method of manufacturing a full-fashioned knitted marine fender ball structure according to any one of claims 1 to 7, wherein the method comprises the steps of: providing a plurality of elongate knitted elements; and interconnecting the plurality of elongate knitted elements to form the full-fashioned knitted marine fender ball structure. The method comprises: Step 1, knitting the bottom opening area, first, using the front and back needle bed against the needle arrangement method, 1 needle interlacing single-face knitting, completing the starting knitting of the opening part, using the double-face knitting method of four plain stitches on both sides, completing the starting knitting of the closed part; then using the front and back needle bed against the needle method to knit the air layer organization, continuing the starting knitting in the middle, switching to full needle plain stitch normal knitting after 2 rows, knitting plain stitches on both sides, forming the opening state and the cylindrical structure of the bottom of the ball structure; Step 2, knitting the bottom arc initial structure area, using local knitting, the front and back needle beds are full needle knitting, the two sides are partially stopped by the needle arrangement method, so that there are old loops on both sides, and the middle part is new loop knitting, completing the knitting of the bottom arc initial structure of the ball structure; Step 3, knitting the bottom shaping needle adjusting area, inserting local knitting into the cylindrical knitting area according to a certain proportion by adding needles, ensuring that the bottom circular arc is first sharp and then slow, and the stopped edge adopts the tuck stitch method to connect the stopped part fabric and the plain stitch fabric, completing the knitting of the bottom arc of the ball structure; Step 4, knitting the middle wear-resistant area, using the front and back needle bed against the needle method to knit the air layer organization, that is, using cylindrical knitting of the front and back needle beds, forming the knitting of the main body area of the ball structure; Step 5, knitting the top shaping needle adjusting area, using local knitting, inserting local knitting into the cylindrical knitting area according to a certain proportion, ensuring that the top circular arc of the area is first slow and then sharp; Step 6, top arc initial construction area knitting, the front and back needle bed middle partial knitting method remains unchanged, the front and back needle bed two sides take the row by row knitting and needle collection method to complete the top knitting of the ball structure; Step 7, neck opening area knitting, using cylindrical knitting method, reducing the number of needles, knitting the required neck height, and finally flat collection needle to end the knitting.

9. A method of making a fully formed knitted marine fender ball structure according to claim 8, wherein, In step 4, during the cylindrical knitting process of the front and back needle bed, the transverse blocking structure knitting is carried out at the same time, and dense double rib structure is knitted in the middle area of the front and back needle bed, which forms a fabric blocking area, so that the ball structure physically separates the left and right air chambers.

10. A method of making a fully formed knitted marine fender ball structure according to claim 8 or 9, wherein, In steps 3 and 5, the partial knitting every 6 rows as a cycle, can be inserted gradually every 2 rows, 4 rows, 6 rows of partial knitting.

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