Seven-area warp-knitted spacer fabric containing functional fibers and preparation method of seven-area warp-knitted spacer fabric

Abstract

The invention discloses a seven-area warp-knitted spacer fabric containing functional fibers and a preparation method of the seven-area warp-knitted spacer fabric, and relates to the technical field of spacer fabric preparation. The seven-area warp-knitted spacer fabric is sequentially provided with seven functional areas in the length direction of the fabric and comprises a front face yarn layer composed of blended yarn of modified wormwood fiber and polyester fiber, a back face yarn layer composed of blended yarn of bamboo charcoal fiber and polyester fiber and a middle spacer layer composed of polyester low stretch yarn connecting the front face yarn layer and the back face yarn layer. Wherein the modified wormwood fiber is obtained by performing composite modification on wormwood fiber through plasma and biological enzyme; in the middle spacing layer of every two adjacent functional areas, the linear density and / or the coil density of the polyester low stretch yarn are / is different. The antibacterial and adsorption dual-function lasting cooperation is achieved, seven-area supporting is precisely matched, the boundary is clear, transition is natural, and the production efficiency and the product quality stability are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of spacer fabric preparation technology, specifically to a warp-knitted spacer fabric with a front yarn containing modified artemisia fiber and a back yarn containing bamboo charcoal fiber, and a seven-zone division achieved by adjusting the thickness and density of the intermediate spacer yarn, and its preparation method. Background Technology

[0002] Warp-knitted spacer fabric is a three-dimensional fabric structure composed of double-sided yarn layers and intermediate connecting yarns (spacer yarns). Due to its excellent breathability, resilience, and customizable support functions, it is widely used in mattresses, seat cushions, and medical care pads. To add additional functions, the industry often introduces functional fibers into the yarn.

[0003] Artemisia fiber has attracted attention due to its natural antibacterial and soothing properties, and its use in fabric functionalization has been explored. However, natural artemisia fiber has significant drawbacks: firstly, its antibacterial components are mostly volatile or water-soluble small molecules, resulting in insufficient antibacterial durability; secondly, the fiber itself has low strength, making it prone to breakage during high-speed weaving, affecting production efficiency and fabric mechanical properties. These shortcomings limit its application in scenarios requiring high-frequency washing or high-strength durability.

[0004] Bamboo charcoal fiber is known for its porous structure and adsorption properties, effectively absorbing formaldehyde, odors, and regulating moisture. However, fabrics made solely of bamboo charcoal fiber have limited functionality and cannot meet consumers' demands for multifunctional and composite products.

[0005] In fabric structure design, to adapt to the differentiated needs of different parts of the human body for pressure distribution, breathability, and functionality, the concept of zoned design has been introduced. Existing seven-zone warp-knitted spacer fabrics mostly achieve zoning by changing the density of the face yarn or the material of the ground yarn, but this approach has significant limitations: Poor weaving coordination: It is difficult to weave the double-sided functional yarn and the intermediate spacer yarn together on a high-speed warp knitting machine. Problems such as yarn entanglement and uneven weaving are likely to occur, resulting in blurred partition boundaries and stiff performance transitions.

[0006] Severe damage to functional fibers: Traditional finishing processes can damage the active structure of functional fibers.

[0007] Low production efficiency and insufficient precision: In the existing technology, the switching of the interval yarn parameters required for different zones mostly depends on manual yarn replacement. Each time a zone is switched, it often requires a 5-10 minute downtime. This not only results in low production efficiency but also large human error, leading to unstable zone size and performance, making it difficult to meet the quality uniformity requirements of industrialized and large-scale production. Summary of the Invention

[0008] In order to solve the problems existing in the prior art, the present invention aims to provide a seven-zone warp-knitted spacer fabric containing functional fibers and its preparation method. The seven-zone warp-knitted spacer fabric has a dual-functional surface layer and a seven-zone differentiated support structure. The preparation method is efficient and can effectively retain the performance of the functional fibers.

[0009] This invention provides the following technical solution: In a first aspect, the present invention provides a seven-zone warp-knitted spacer fabric containing functional fibers, wherein seven functional zones are sequentially arranged along the length of the fabric, comprising: The front veil layer is composed of a blended yarn of modified artemisia fiber and polyester fiber; the modified artemisia fiber is obtained by plasma and bio-enzyme composite modification of artemisia fiber; The reverse side yarn layer is composed of a blend of bamboo charcoal fiber and polyester fiber. The intermediate spacer layer is composed of intermediate spacer yarns connecting the two yarn layers; the intermediate spacer yarns are made of low-elasticity polyester yarns. In particular, the linear density and / or coil density of the intermediate spacer wires in the intermediate spacer layer of two adjacent functional areas are different.

[0010] Furthermore, in the front veil layer, the mass ratio of modified Artemisia argyi fiber to polyester fiber is (35-55):(45-65).

[0011] Preferably, the length of the mugwort fiber is 38-42 mm and the fineness is 1.2-1.5 dtex, and the fineness of the polyester fiber is 1.5-2.0 dtex and the length is 38-40 mm.

[0012] Furthermore, the front veil layer is loaded with chitosan quaternary ammonium salt.

[0013] Furthermore, the modified Artemisia argyi fiber is prepared by the following method: a. Soak natural mugwort fibers in deionized water at 50-60℃ for 30-40 minutes to remove surface impurities, and then dry until the moisture content is ≤8%; b. Plasma treatment: Using argon as the working gas, plasma treatment is carried out for 15-20 seconds at a power of 80-100W to etch the fiber surface and form micropores with a diameter of 0.5-2μm on the surface, thereby increasing the specific surface area of ​​the fiber. c. Bioenzyme modification: Prepare a cellulase solution with a pH of 4.5-5.0 and a concentration of 2-3 g / L. Immerse the plasma-treated Artemisia argyi fiber in the cellulase solution and react at a constant temperature of 50-55℃ for 60-80 minutes. Terminate the reaction, wash with water until neutral, and dry to obtain the modified Artemisia argyi fiber.

[0014] Furthermore, the reverse side of the yarn layer contains ≥30% bamboo charcoal fiber by mass.

[0015] Furthermore, the blended yarn of bamboo charcoal fiber and polyester fiber is prepared by the following method: after blending bamboo charcoal fiber and polyester fiber, it is drawn twice (drawing speed 250-300m / min), and then spun into 28-32S blended yarn (twist coefficient 340-360) by air-jet spinning process.

[0016] Preferably, the intermediate spacer wire is prepared by the following method: Raw material selection: Bottle-grade polyester chips with an intrinsic viscosity of 1.15±0.015 DL / g, end carboxyl content of 12±2 mmol / kg, and melting point ≤255℃ are used.

[0017] Filament drawing: After melting and drawing the slicing, high-strength polyester low-elasticity yarn is formed (breaking strength ≥2.5N / dtex, elongation: 12%~30%), linear density range 150D-600D (divided into 4 specifications according to the requirements of Zone 7).

[0018] Post-treatment: Place the spacer yarn in a hot air environment at 150-200℃ for 10-15 minutes for pre-shrinkage treatment (pre-shrinkage rate 2%-3%) to avoid dimensional deformation of the woven fabric.

[0019] Furthermore, in the intermediate spacer layer of the seven functional zones, the linear density and coil density of the polyester low-elasticity yarn are as follows: Zone 1 and Zone 7: Line density is 150-200D, coil density is 15-18 coils / cm; Zones 2 and 6: Line density is 200-250D, coil density is 12-15 coils / cm; Zones 3 and 5: Line density is 250-300D, coil density is 10-12 coils / cm; Zone 4: Line density is 300-350D, and coil density is 8-10 coils / cm.

[0020] Furthermore, the linear density and / or coil of the polyester low-elasticity yarn between two adjacent functional areas are switched in a gradual transition manner.

[0021] Furthermore, the width of the boundary transition area between adjacent functional areas is ≤5mm.

[0022] Secondly, the present invention also provides a method for preparing the above-mentioned seven-zone warp-knitted spacer fabric containing functional fibers, comprising the following steps: S1. Raw material pretreatment: Prepare a blended yarn of modified Artemisia argyi fiber and polyester fiber as the front yarn, prepare a blended yarn of bamboo charcoal fiber and polyester fiber as the back yarn, and prepare polyester low elastic yarn with different linear densities as intermediate spacer yarn. S2, Seven-zone warp knitting: Using a double-needle bed electronic needle selection warp knitting machine, the front yarn, back yarn and spacer yarn are warped by independent warp feeding and electronic needle selection zone control through double yarn frames. Based on the preset seven-zone distribution, the spacer yarn with different linear densities is automatically switched during the knitting process to form seven functional zones. S3. Perform functional retention finishing on the woven fabric: sequentially perform water washing, hot air setting and functional enhancement finishing on the woven fabric; The hot air setting process is performed at least three times, with each hot air setting process taking 30-60 seconds at a temperature of 170-180℃.

[0023] Furthermore, the functional enhancement finishing includes: treating the front side of the fabric with a chitosan quaternary ammonium salt solution, and adsorbing and activating the reverse side of the fabric with a weakly acidic solution.

[0024] Preferably, the functional enhancements specifically include: Antibacterial enhancement: Prepare a 0.3-0.5 g / L chitosan quaternary ammonium salt solution (pH 6.0-6.5), treat the front side of the fabric with the padding method (70%-75% padding rate), and then dry it at a temperature of 80-85℃, thereby forming "double antibacterial" with the modified Artemisia argyi fiber; Adsorption activation: Soak the reverse side of the fabric in a weakly acidic aqueous solution (pH 5.0-5.5) at 50-60℃ for 10-15 minutes to activate the bamboo charcoal adsorption channels, and then air dry naturally to further improve the formaldehyde adsorption rate.

[0025] Preferably, in step S2, an electronic warp feeding system is used to automatically adjust the amount of warp feed for the interval yarn according to the preset parameters of the seven zones. The response time for switching parameters in each zone is ≤0.5 seconds, and the weaving process does not require stopping the machine.

[0026] Preferably, in step S2, the parameters for warp knitting are: Stitch length: 14-18 stitches / inch (select according to the required fabric density; 16 stitches / inch for mattresses and 18 stitches / inch for nursing pads). Weaving speed: 800-1000 rpm (the speed remains stable during the seven-zone switching, and there is no need to stop the machine); Warp feeding system: The front yarn layer adopts passive warp feeding with a feeding rate of 850-950 meters / hour; the reverse yarn layer adopts active warp feeding with a feeding rate of 750-850 meters / hour; the intermediate spacer yarn adopts an electronic warp feeding system (EBA), which precisely controls the warp feeding rate according to the parameters of the seven zones.

[0027] Preferably, step S2 further includes real-time monitoring of the tension of the front yarn (tension controlled at 25-30 cN), the back yarn (tension controlled at 20-25 cN), and the intermediate spacer yarn (tension controlled at 30-35 cN) by the tension sensor of the warp knitting machine, and automatically adjusting the warp feed speed when the deviation exceeds ±2 cN.

[0028] Preferably, the spacing wire parameters between adjacent regions adopt a gradual transition to avoid hard boundaries. The gradual transition can be a sequential transition with a fixed number of steps or a gradual transition with a fixed number of varying steps per step. Preferably, the gradual transition is a sequential transition with 3 steps, or a gradual transition with 50D per step.

[0029] Preferably, step S2 also includes a yarn breakage detection and alarm system. Specifically, each yarn is equipped with a photoelectric yarn breakage detector, which stops the machine and alarms within 0.3 seconds after a yarn breakage, to ensure the continuity of weaving.

[0030] Preferably, the water washing is performed by adding 0.5-1 g / L of a nonionic surfactant (such as fatty alcohol polyoxyethylene ether) to soft water at 40-45℃ and washing for 15-20 minutes to remove the weaving oil.

[0031] Through the above design, the present invention has the following effects: This invention utilizes a composite structure design of modified Artemisia argyi fiber on the front and bamboo charcoal fiber on the back, enabling a single fabric to possess both excellent antibacterial and adsorption functions, thus solving the problem of limited functionality in traditional functional fabrics. Plasma-bioenzyme composite modification of the Artemisia argyi fiber enhances its antibacterial durability. By configuring spacer yarns with specific linear and coil densities for different functional zones, the fabric achieves seven ergonomically designed zones with varying degrees of firmness along its length, adapting to the different needs of various parts of the human body for different levels of firmness, resulting in a more ergonomic fit during use. Furthermore, its manufacturing process is highly mechanized, enabling online automatic switching of the spacer yarn parameters across the seven zones. The switching response time is short and requires no machine downtime, improving production efficiency while enhancing the consistency of the product's mechanical properties and dimensional stability. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the overall process for preparing a seven-zone warp-knitted spacer fabric containing functional fibers, as provided in Embodiment 1 of the present invention.

[0034] Figure 2This is a schematic diagram of the seven-zone structure of a seven-zone warp-knitted spacer fabric containing functional fibers provided in Embodiment 1 of the present invention.

[0035] Figure 3 This is a cross-sectional schematic diagram of a seven-zone warp-knitted spacer fabric containing functional fibers provided in Embodiment 1 of the present invention.

[0036] The markings in the diagram are as follows: 1-Front veil layer; 2-Back veil layer; 3-Intermediate spacer layer; 4-Zone 1; 5-Zone 2; 6-Zone 3; 7-Zone 4; 8-Zone 5; 9-Zone 6; 10-Zone 7. Detailed Implementation

[0037] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] It should be understood that, when used in this specification and the appended claims, the terms “comprising” and “including” indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0039] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0040] It should be noted that in the following embodiments, the selection of raw materials and the drawing process of the intermediate spacer yarn are conventional techniques, and it is only necessary to obtain polyester low elastic yarn with a fixed linear density, a breaking strength ≥2.5N / dtex, and an elongation of 12%~30%.

[0041] In the following embodiments of the present invention, the preparation method is as follows: Slice pretreatment The slices are placed in a drying oven and dried at 120-180℃ for 4-8 hours to reduce the moisture content to below 50ppm. (2) Melt extrusion The dried slices are fed into a screw extruder and melted into a homogeneous melt by heating the barrel (260-290℃).

[0042] The melt is filtered through a screen to remove impurities, and then extruded through the micropores (0.1-0.3 mm in diameter) of the spinneret to form a continuous filament.

[0043] (3) Cooling and curing The extruded filaments immediately enter the cooling air chamber or cooling water tank and are rapidly cooled with air or water at 20-30°C.

[0044] After the molten filament cools and solidifies, it forms an amorphous nascent filament (POY filament, pre-oriented filament).

[0045] (4) Stretch orientation The nascent filament is stretched (3-5 times) at a certain temperature (80-120℃) by multiple sets of drawing rollers.

[0046] (5) Heat setting After being stretched, the filaments are placed in a heat-setting chamber and kept at 150-220℃ to eliminate the internal stress generated by stretching.

[0047] Example 1 A seven-zone warp-knitted spacer fabric containing functional fibers, wherein seven functional zones are arranged sequentially along the length of the fabric, such as... Figure 3 As shown, zones 1-4, 2-5, 3-6, 4-7, 5-8, 6-9, and 7-10 are respectively. In this embodiment, the seven-zone warp-knitted spacer fabric containing functional fibers is used in the mattress. Zone 1-4 corresponds to the human neck, zone 2-5 corresponds to the human shoulder, zone 3-6 corresponds to the human back, zone 4-7 corresponds to the human waist / hips, zone 5-8 corresponds to the lower back, zone 6-9 corresponds to the upper leg, and zone 7-10 corresponds to the lower leg.

[0048] Specifically, such as Figure 2 As shown, the seven-zone warp-knitted spacer fabric containing functional fibers includes: The front veil layer 1 is composed of a blended yarn of modified artemisia fiber and polyester fiber; the modified artemisia fiber is obtained by plasma and bio-enzyme composite modification of artemisia fiber; The reverse yarn layer 2 is composed of a blend of bamboo charcoal fiber and polyester fiber. The intermediate spacer layer 3 is composed of intermediate spacer yarns connecting the front and back yarn layers; the intermediate spacer yarns are made of low-elasticity polyester yarns. In particular, the linear density and / or coil density of the intermediate spacer wires in the intermediate spacer layer 3 between two adjacent functional areas are different.

[0049] The preparation method of the above-mentioned seven-zone warp-knitted spacer fabric containing functional fibers includes the following steps (such as...) Figure 1 (as shown) S1, Raw material pretreatment (1) Preparation of the front veil: Pretreatment: Weigh 1 kg of natural mugwort fiber (40 mm in length, 1.3 dtex in fineness), soak it in deionized water at 55°C for 35 minutes, and then dry it in an oven at 85°C until the moisture content is 7%.

[0050] Plasma treatment: The dried Artemisia argyi fibers were placed in a low-temperature plasma treatment instrument, and argon gas was introduced. The treatment was carried out for 18 seconds at a power of 90W.

[0051] Bioenzyme modification: A cellulase solution with a concentration of 2.5 g / L and a pH of 4.8 was prepared. The plasma-treated Artemisia argyi fibers were immersed in this solution and reacted in a constant temperature water bath at 52℃ for 70 minutes. The reaction was then terminated by adding 0.1 mol / L NaOH solution, washed with water until neutral, and dried to obtain modified Artemisia argyi fibers.

[0052] Blending: Modified Artemisia argyi fiber and polyester fiber (fineness 1.8 dtex, length 39 mm) are blended at a mass ratio of 45:55. The blended yarn is spun into 38S blended yarn using ring spinning process, with a twist coefficient set at 370.

[0053] (2) Preparation of the reverse side of the veil: Bamboo charcoal fiber was blended with polyester fiber (fineness 1.3 dtex, length 40 mm) to obtain a bamboo charcoal-polyester blended fiber with a bamboo charcoal fiber mass content of 35%.

[0054] The fibers were drawn twice at a speed of 280 m / min. Then, an air-jet spinning process was used to spin a 30S blended yarn with a twist coefficient of 350.

[0055] (3) Preparation and pretreatment of the intermediate spacer layer (polyester low elasticity yarn): Bottle-grade polyester chips (CZ-318) with an intrinsic viscosity of 1.15 DL / g were selected.

[0056] Four linear densities of polyester low-elasticity yarn were prepared using a melt drawing process: 180D, 220D, 280D, and 320D.

[0057] The polyester low-elasticity yarn obtained by drawing is placed in a hot air environment at 180°C for pre-shrinking treatment for 12 minutes.

[0058] S2, Seventh Zone Warp Knitting The knitting was performed using a double-needle-bed electronic needle selection warp knitting machine (model: KS4-EL).

[0059] Basic equipment parameters: stitch length set to 16 stitches / inch (for mattresses), knitting speed set to 900 rpm.

[0060] Scripture delivery system settings: Front veil (modified mugwort yarn): adopts passive warp feeding, with the feeding rate set at 900 meters / hour.

[0061] Reverse side yarn (bamboo charcoal yarn): adopts active warp feeding, with the warp feeding rate set at 800 meters / hour.

[0062] Intermediate spacer wire: Electronic warp feeding system (EBA) is used, and the amount of warp fed in each zone is controlled by a preset program.

[0063] Seven-zone weaving procedure and execution: The preset program divides the fabric into seven functional zones along its length. The parameters of the spacer yarns and the warp feed amount for each zone are set as shown in Table 1 below: Table 1. Parameters and warp feed of the seven-zone intermediate spacer yarn in Example 1 During knitting, the machine executes the program automatically. When switching from one functional area to the next, the electronic needle selector switches the spacing yarn specification, and the electronic warp feed system synchronously switches the warp feed amount. The response time for the entire switching process is 0.4 seconds, and knitting continues without stopping the machine.

[0064] Process control: Tension control: The system monitors the tension of the three yarns in real time. The set values ​​are: 28cN for the front yarn, 23cN for the back yarn, and 32cN for the intermediate spacer yarn. When the measured tension deviation exceeds ±2cN, the system automatically adjusts the warp feed speed to restore the set tension.

[0065] Gradual transition control: When switching between adjacent functional areas (such as zone one and zone two), the program controls the process of changing the linear density of the spacer yarn from 180D to 220D, which is completed linearly within three consecutive weaving rows, achieving a natural transition at the boundary.

[0066] Yarn breakage detection: Each yarn path is equipped with a photoelectric detector, which can trigger a machine stop and alarm within 0.3 seconds after a yarn breakage.

[0067] S3, Post-finishing process (1) Washing and setting: Washing: Add 0.8 g / L of fatty alcohol polyoxyethylene ether (AEO-9) to soft water at 42℃, and immerse the woven fabric for 18 minutes to fully remove the oil.

[0068] Hot air setting: A three-stage setting process is used.

[0069] First pass: Temperature 175℃, weaving speed 23.5 m / min, width after shaping 160cm.

[0070] Second pass: Temperature 175℃, weaving speed 22 m / min, width after shaping 220cm.

[0071] Third pass: Temperature 180℃, weaving speed 20 m / min, width after shaping 210cm.

[0072] (2) Functional enhancements and improvements: Antibacterial enhancement: Prepare a 0.4 g / L chitosan quaternary ammonium salt solution with a pH of 6.2. Pulp the solution onto the front side of the fabric, controlling the pick-up rate to 72%, and then dry it in an oven at 82°C.

[0073] Adsorption activation: Prepare a weak acetic acid aqueous solution at 55℃ and pH 5.2. Immerse the reverse side of the fabric in the solution for 12 minutes, then remove and air dry naturally.

[0074] Softening treatment: Prepare a 1.2 g / L polydimethylsiloxane softener solution, paddle treat the fabric at 42°C with a paddle rate of 72%, and then dry at 82°C.

[0075] After inspection and warehousing, a seven-zone warp-knitted spacer fabric containing functional fibers was obtained.

[0076] Example 2 A seven-zone warp-knitted spacer fabric containing functional fibers, wherein seven functional zones are sequentially arranged along the length of the fabric, comprising: The front veil layer is composed of a blended yarn of modified artemisia fiber and polyester fiber; the modified artemisia fiber is obtained by plasma and bio-enzyme composite modification of artemisia fiber; The reverse side yarn layer is composed of a blend of bamboo charcoal fiber and polyester fiber. The intermediate spacer layer is composed of intermediate spacer yarns connecting the two sides of the yarn layer; the intermediate spacer yarns are made of low-elasticity polyester yarn. In the intermediate spacer layer between two adjacent functional areas, the linear density and / or coil density of the intermediate spacer wire are different.

[0077] The preparation method of the above-mentioned seven-zone warp-knitted spacer fabric containing functional fibers includes the following steps: S1, Raw material pretreatment (1) Preparation of the front veil: Pretreatment: Weigh 1 kg of natural mugwort fiber (38 mm in length, 1.2 dtex in fineness), soak it in deionized water at 50°C for 40 minutes, and then dry it in an oven at 80°C until the moisture content is 8%.

[0078] Plasma treatment: The dried Artemisia argyi fibers are placed in a low-temperature plasma treatment instrument, argon gas is introduced, and the treatment is carried out for 20 seconds at a power of 80W.

[0079] Bioenzyme modification: A cellulase solution with a concentration of 2.0 g / L and a pH of 5.0 was prepared. The plasma-treated Artemisia argyi fibers were immersed in this solution and reacted in a constant temperature water bath at 55℃ for 60 minutes. The reaction was then terminated by adding 0.1 mol / L NaOH solution, washed with water until neutral, and dried to obtain modified Artemisia argyi fibers.

[0080] Blending: Modified Artemisia argyi fiber and polyester fiber (fineness 2.0 dtex, length 38 mm) are blended at a mass ratio of 35:65. The blended yarn is spun into 32S blended yarn using ring spinning process, with a twist coefficient set at 360.

[0081] (2) Preparation of the reverse side of the veil: Bamboo charcoal fiber was blended with polyester fiber (fineness 1.5 dtex, length 38 mm) to obtain a bamboo charcoal-polyester blended fiber with a bamboo charcoal fiber content of 30%.

[0082] The fibers were drawn twice at a speed of 250 m / min. Then, an air-jet spinning process was used to spin a 28S blended yarn with a twist coefficient of 340.

[0083] (3) Preparation and pretreatment of the intermediate spacer layer (polyester low elasticity yarn): Bottle-grade polyester chips (CZ-318) with an intrinsic viscosity of 1.15 DL / g were selected.

[0084] Four linear densities of polyester low-elasticity yarn were prepared using a melt drawing process: 150D, 200D, 250D, and 300D.

[0085] The polyester low-elasticity yarn obtained by drawing is placed in a hot air environment at 170℃ for pre-shrinking treatment for 15 minutes.

[0086] S2, Seventh Zone Warp Knitting The knitting was performed using a double-needle-bed electronic needle selection warp knitting machine (model: KS4-EL).

[0087] Basic equipment parameters: stitch length set to 18 stitches / inch (for mattresses), knitting speed set to 800 rpm.

[0088] Scripture delivery system settings: Frontal veil: A passive method of warp delivery is adopted, with the delivery rate set at 800 meters per hour.

[0089] Reverse veil: Active warp feeding is adopted, with the warp feeding rate set at 750 meters / hour.

[0090] Intermediate spacer wire: Electronic warp feeding system (EBA) is used, and the amount of warp fed in each zone is controlled by a preset program.

[0091] Seven-zone weaving procedure and execution: The preset program divides the fabric into seven functional zones along its length. The parameters of the spacer yarns and the amount of warp feed for each zone are set as shown in Table 2 below: Table 2. Parameters and warp feed of the intermediate spacer yarn in zone 7 of Example 2 During knitting, the machine executes the program automatically. When switching from one functional area to the next, the electronic needle selector switches the spacing yarn specification, and the electronic warp feed system synchronously switches the warp feed amount. The response time for the entire switching process is 0.5 seconds, and knitting continues continuously without stopping the machine.

[0092] Process control: Tension control: The system monitors the tension of the three yarns in real time. The set values ​​are: 25cN for the front yarn, 20cN for the back yarn, and 30cN for the intermediate spacer yarn. When the measured tension deviation exceeds ±2cN, the system automatically adjusts the warp feed speed to restore the set tension.

[0093] Gradual transition control: When switching between adjacent functional areas (such as zone one and zone two), the program controls the linear density of the spacer yarn to change from 150D to 200D, which is completed linearly within three consecutive weaving rows, achieving a natural transition at the boundary.

[0094] Yarn breakage detection: Each yarn path is equipped with a photoelectric detector, which can trigger a machine stop and alarm within 0.3 seconds after a yarn breakage.

[0095] S3, Post-finishing process (1) Washing and setting: Washing: Add 0.5g / L of fatty alcohol polyoxyethylene ether (AEO-9) to soft water at 40℃, and soak the woven fabric for 20 minutes to fully remove the oil.

[0096] Hot air setting: A three-stage setting process is used.

[0097] First pass: Temperature 170℃, weaving speed 24 m / min, width after shaping 160cm.

[0098] Second pass: Temperature 175℃, weaving speed 22 m / min, width after shaping 220cm.

[0099] Third pass: Temperature 180℃, weaving speed 20 m / min, width after shaping 210cm.

[0100] (2) Functional enhancements and improvements: Antibacterial enhancement: Prepare a 0.3 g / L chitosan quaternary ammonium salt solution with a pH of 6.0. Pulp the solution onto the front side of the fabric, controlling the pick-up rate to 70%, and then dry it in an oven at 80°C.

[0101] Adsorption activation: Prepare a weak acetic acid aqueous solution at 50℃ and pH 5.0. Immerse the reverse side of the fabric in the solution for 15 minutes, then remove and air dry naturally.

[0102] Softening treatment: Prepare a 1.0 g / L polydimethylsiloxane softener solution, paddle the fabric at 40°C with a paddle rate of 70%, and then dry at 80°C.

[0103] After inspection and warehousing, a seven-zone warp-knitted spacer fabric containing functional fibers was obtained.

[0104] Example 3 A seven-zone warp-knitted spacer fabric containing functional fibers, wherein seven functional zones are sequentially arranged along the length of the fabric, comprising: The front veil layer is composed of a blended yarn of modified artemisia fiber and polyester fiber; the modified artemisia fiber is obtained by plasma and bio-enzyme composite modification of artemisia fiber; The reverse side yarn layer is composed of a blend of bamboo charcoal fiber and polyester fiber. The intermediate spacer layer is composed of intermediate spacer yarns connecting the two yarn layers; the intermediate spacer yarns are made of low-elasticity polyester yarns. In the intermediate spacer layer between two adjacent functional areas, the linear density and / or coil density of the intermediate spacer wire are different.

[0105] The preparation method of the above-mentioned seven-zone warp-knitted spacer fabric containing functional fibers includes the following steps: S1, Raw material pretreatment (1) Preparation of the front veil: Pretreatment: Weigh 1 kg of natural mugwort fiber (42 mm in length, 1.5 dtex in fineness), soak it in deionized water at 60°C for 30 minutes, and then dry it at 55°C until the moisture content is 7%.

[0106] Plasma treatment: The dried Artemisia argyi fibers are placed in a low-temperature plasma treatment instrument, argon gas is introduced, and the treatment is carried out for 15 seconds at a power of 100W.

[0107] Bioenzyme modification: A cellulase solution with a concentration of 3.0 g / L and a pH of 4.5 was prepared. The plasma-treated Artemisia argyi fibers were immersed in this solution and reacted in a constant temperature water bath at 50°C for 80 minutes. The reaction was then terminated by adding 0.1 mol / L NaOH solution, washed with water until neutral, and dried to obtain modified Artemisia argyi fibers.

[0108] Blending: Modified Artemisia argyi fiber and polyester fiber (fineness 1.5 dtex, length 40 mm) are blended at a mass ratio of 45:55. The blended yarn is spun into 40S blended yarn using ring spinning process, with a twist coefficient set at 380.

[0109] (2) Preparation of the reverse side of the veil: Bamboo charcoal fiber was blended with polyester fiber (fineness 1.2 dtex, length 42 mm) to obtain a bamboo charcoal-polyester blended fiber with a bamboo charcoal fiber content of 40%.

[0110] The fibers were drawn twice at a speed of 300 m / min. Then, an air-jet spinning process was used to spin a 32S blended yarn with a twist coefficient of 360.

[0111] (3) Preparation and pretreatment of the intermediate spacer layer (polyester low elasticity yarn): Bottle-grade polyester chips (CZ-318) with an intrinsic viscosity of 1.15 DL / g were selected.

[0112] Four linear densities of polyester low-elasticity yarn were prepared using a melt drawing process: 200D, 250D, 300D, and 350D.

[0113] The polyester low-elasticity yarn obtained by drawing is placed in a hot air environment at 200℃ and pre-shrinked for 10 minutes.

[0114] S2, Seventh Zone Warp Knitting The knitting was performed using a double-needle-bed electronic needle selection warp knitting machine (model: KS4-EL).

[0115] Basic equipment parameters: stitch length set to 14 stitches / inch (for mattresses), knitting speed set to 1000 rpm.

[0116] Scripture delivery system settings: Frontal veil: A passive method of delivering the scripture is adopted, with the delivery rate set at 1000 meters per hour.

[0117] Reverse veil: Active warp feeding is adopted, with the warp feeding rate set at 900 meters / hour.

[0118] Intermediate spacer wire: Electronic warp feeding system (EBA) is used, and the amount of warp fed in each zone is controlled by a preset program.

[0119] Seven-zone weaving procedure and execution: The preset program divides the fabric into seven functional zones along its length. The parameters of the spacer yarns and the amount of warp feed for each zone are set as shown in Table 3 below: Table 3. Parameters and warp feed of the intermediate spacer yarn in zone 7 of Example 3 During knitting, the machine executes the program automatically. When switching from one functional area to the next, the electronic needle selector switches the spacing yarn specification, and the electronic warp feed system synchronously switches the warp feed amount. The response time for the entire switching process is 0.3 seconds, and knitting continues continuously without stopping the machine.

[0120] Process control: Tension control: The system monitors the tension of the three yarns in real time. The set values ​​are: 30cN for the front yarn, 25cN for the back yarn, and 35cN for the intermediate spacer yarn. When the measured tension deviation exceeds ±2cN, the system automatically adjusts the warp feed speed to restore the set tension.

[0121] Gradual transition control: When switching between adjacent functional areas (such as zone one and zone two), the program controls the process of changing the linear density of the spacer yarn from 180D to 220D, which is completed linearly within three consecutive weaving rows, achieving a natural transition at the boundary.

[0122] Yarn breakage detection: Each yarn path is equipped with a photoelectric detector, which can trigger a machine stop and alarm within 0.3 seconds after a yarn breakage.

[0123] S3, Post-finishing process (1) Washing and setting: Washing: Add 1.0 g / L of fatty alcohol polyoxyethylene ether (AEO-9) to soft water at 45℃, and soak the woven fabric for 15 minutes to fully remove the oil.

[0124] Hot air setting: A three-stage setting process is used.

[0125] First pass: Temperature 175℃, weaving speed 23.5 m / min, width after shaping 160cm.

[0126] Second pass: Temperature 175℃, weaving speed 22 m / min, width after shaping 220cm.

[0127] Third pass: Temperature 180℃, weaving speed 20 m / min, width after shaping 210cm.

[0128] (2) Functional enhancements and improvements: Antibacterial enhancement: Prepare a 0.5 g / L chitosan quaternary ammonium salt solution with a pH of 6.5. Pulp the solution onto the front side of the fabric, controlling the pick-up rate to 75%, and then dry it in an oven at 85°C.

[0129] Adsorption activation: Prepare a weak acetic acid aqueous solution at 60℃ and pH 5.5. Immerse the reverse side of the fabric in the solution for 10 minutes, then remove and air dry naturally.

[0130] Softening treatment: Prepare a 1.5 g / L polydimethylsiloxane softener solution, paddle the fabric at 45°C with a paddle rate of 75%, and then dry at 85°C.

[0131] After inspection and warehousing, a seven-zone warp-knitted spacer fabric containing functional fibers was obtained.

[0132] To verify the technical effects of the present invention, comparative examples are set up based on Example 1 as follows: Comparative Example 1 The only difference between this comparative example and Example 1 is that the same amount of unmodified Artemisia argyi fiber was used to replace the modified Artemisia argyi fiber.

[0133] Comparative Example 2 The only difference between this comparative example and Example 1 is that no bio-enzyme modification was performed in step S1.

[0134] Comparative Example 3 The only difference between this comparative example and Example 1 is that plasma treatment was not performed in step S1.

[0135] Comparative Example 4 The only difference between this comparative example and Example 1 is that the front veil layer is composed of polyester fibers and does not include modified artemisia fibers.

[0136] Comparative Example 5 The only difference between this comparative example and Example 1 is that the reverse side of the yarn layer is composed of polyester fibers and does not include bamboo charcoal fibers.

[0137] Comparative Example 6 The only difference between this comparative example and Example 1 is that in step S3, hot air setting is performed only once, and the temperature is 190°C.

[0138] To verify the technical effects of the present invention, the fabrics of the embodiments and comparative examples were subjected to the following effect tests: Antibacterial performance test To verify the antibacterial effect of the present invention, antibacterial tests were conducted on Examples 1-3 and Comparative Example 4.

[0139] Test method: GB / T 20944.3-2008; sterilization method: autoclaving; working solution: 0.03 mol / L phosphate buffer; contact time: 18 hours; test sample: 0.75 g. Test results are shown in Table 4 below: Table 4. Antibacterial effects of Examples 1-3 and Comparative Example 4 As shown in Table 4, Examples 1-3 of the present invention all have good antibacterial effects.

[0140] Furthermore, to verify the effect of modified Artemisia argyi fiber on the antibacterial properties of fabrics, antibacterial durability tests were conducted on Examples 1-3 and Comparative Examples 1-3.

[0141] Test method: The antibacterial rates (before washing) and after 50 washes of Examples 1-3 and Comparative Examples 1-3 were tested according to GB / T 20944.3-2008. The test results are shown in Table 5. Table 5. Antibacterial effects of Examples 1-3 and Comparative Examples 1-3 before and after water washing. As shown in Table 5, after 50 standard washes, the inhibition rates of Comparative Examples 1-3 against Staphylococcus aureus and Escherichia coli decreased significantly. However, the embodiments of the present invention maintained a high inhibition rate under the same washing conditions.

[0142] Adsorption activation test To verify the formaldehyde adsorption effect of the present invention, formaldehyde adsorption tests were conducted on Examples 1-3 and Comparative Example 5.

[0143] Test method: JC / T 1074-2021 Adsorption performance test of indoor air purification materials.

[0144] The test results are shown in Table 6 below: Table 6 Formaldehyde adsorption effect As shown in Table 6, the fabric of the present invention can effectively adsorb formaldehyde.

[0145] Functional area performance test To verify the performance of different functional zones of the present invention, the transition width and tensile strength of the seven-zone warp-knitted spacer fabrics containing functional fibers in Examples 1-3 were tested. The tensile strength was tested according to GB / T 24218.3-2010 Textiles - Nonwovens - Test Methods - Part 3: Determination of breaking strength and elongation at break (strip method). The test results are shown in Table 7 below. Table 7. Transition width and tensile strength test results As shown in Table 7, the seven-zone warp-knitted spacer fabrics containing functional fibers in Examples 1-3 have clear zone boundaries, transition width ≤ 5 mm, and excellent mechanical properties, with warp tensile strength ≥ 320 N / 5 cm and weft tensile strength ≥ 270 N / 5 cm.

[0146] Furthermore, indentation hardness tests were performed on each functional area of ​​Example 1. The test methods and results are shown in Table 8 below: Table 8. Indentation hardness test results for each functional area in the embodiment. As shown in Table 8, Embodiment 1 of the present invention can simultaneously achieve different softness and hardness settings in seven ergonomic zones along the length of the fabric, adapting to the different softness and hardness requirements of various parts of the human body, and making it more in line with the curves of the human body when used as a mattress filling layer.

[0147] Function retention effect Functional retention tests were conducted on Examples 1-3 and Comparative Example 6. The antibacterial rate and formaldehyde adsorption rate were tested before and after hot air setting, and the antibacterial retention rate and formaldehyde adsorption retention rate were calculated. Specifically, the antibacterial retention rate was calculated as (antibacterial rate after hot air setting / antibacterial rate before hot air setting) × 100%; the formaldehyde adsorption retention rate was calculated as (formaldehyde adsorption rate after hot air setting / formaldehyde adsorption rate before hot air setting) × 100%. The test results are shown in Table 9 below. Table 9. Test Results of Function Retention Effect As shown in Table 9, the antibacterial retention rate of the embodiments of the present invention is ≥90%, the adsorption retention rate is ≥85%, while the functional retention rate of Comparative Example 6 is ≤70%, which is significantly lower than the technical solution of the present invention.

[0148] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A seven-zone warp-knitted spacer fabric containing functional fibers, characterized in that, Seven functional zones are arranged sequentially along the length of the fabric, including: The front veil layer is composed of a blended yarn of modified artemisia fiber and polyester fiber; the modified artemisia fiber is obtained by plasma and bio-enzyme composite modification of artemisia fiber; The reverse side yarn layer is composed of a blend of bamboo charcoal fiber and polyester fiber. The intermediate spacer layer is composed of intermediate spacer yarns connecting the two yarn layers; the intermediate spacer yarns are made of low-elasticity polyester yarns. In particular, the linear density and / or coil density of the intermediate spacer wires in the intermediate spacer layer of two adjacent functional areas are different.

2. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, In the front veil layer, the mass ratio of modified Artemisia argyi fiber to polyester fiber is (35-55):(45-65).

3. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, The front veil layer is loaded with chitosan quaternary ammonium salt.

4. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, The modified Artemisia argyi fiber was prepared by the following method: a. Soak natural mugwort fibers in deionized water at 50-60℃ for 30-40 minutes to remove surface impurities, and then dry until the moisture content is ≤8%; b. Plasma treatment: Using argon as the working gas, plasma treatment is performed for 15-20 seconds at a power of 80-100W. c. Bioenzyme modification: Prepare a cellulase solution with a pH of 4.5-5.0 and a concentration of 2-3 g / L. Immerse the plasma-treated Artemisia argyi fiber in the cellulase solution and react at a constant temperature of 50-55℃ for 60-80 minutes. Terminate the reaction, wash with water until neutral, and dry to obtain the modified Artemisia argyi fiber.

5. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, The reverse side of the yarn layer contains ≥30% bamboo charcoal fiber by mass.

6. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, In the intermediate spacer layer of the seven functional zones, the linear density and coil density of the polyester low-elasticity yarn are as follows: Zone 1 and Zone 7: Line density is 150-200D, coil density is 15-18 coils / cm; Zones 2 and 6: Line density is 200-250D, coil density is 12-15 coils / cm; Zones 3 and 5: Line density is 250-300D, coil density is 10-12 coils / cm; Zone 4: Line density is 300-350D, and coil density is 8-10 coils / cm.

7. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, The linear density and / or coil of the polyester low-elasticity yarn between two adjacent functional areas are switched in a gradual transition manner.

8. The seven-zone warp-knitted spacer fabric containing functional fibers as described in claim 1, characterized in that, The width of the boundary transition area between adjacent functional areas is ≤5mm.

9. A method for preparing a seven-zone warp-knitted spacer fabric containing functional fibers as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. Raw material pretreatment: Prepare a blended yarn of modified Artemisia argyi fiber and polyester fiber as the front yarn, prepare a blended yarn of bamboo charcoal fiber and polyester fiber as the back yarn, and prepare polyester low elastic yarn with different linear densities as intermediate spacer yarn. S2, Seven-zone warp knitting: Using a double-needle bed electronic needle selection warp knitting machine, the front yarn, back yarn and spacer yarn are warped by independent warp feeding and electronic needle selection zone control through double yarn frames. Based on the preset seven-zone distribution, the spacer yarn with different linear densities is automatically switched during the knitting process to form seven functional zones. S3. Perform functional retention finishing on the woven fabric: sequentially perform water washing, hot air setting and functional enhancement finishing on the woven fabric; The hot air setting process is performed at least three times, with each hot air setting process taking 30-60 seconds at a temperature of 170-180℃.

10. The method for preparing a seven-zone warp-knitted spacer fabric containing functional fibers as described in any one of claims 1-8, as described in claim 9, characterized in that, The functional enhancement finishing includes: treating the front side of the fabric with a chitosan quaternary ammonium salt solution, and adsorbing and activating the reverse side of the fabric with a weakly acidic solution.

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