Environment-friendly warp-knitted fabric

Abstract

The utility model discloses an environment-friendly warp knitting fabric which comprises a fabric body, the fabric body comprises an extension line surface layer, an internal structure layer and a coil structure surface layer, the internal structure layer is located in the fabric body and connected with the extension line surface layer and the coil structure surface layer, the extension line surface layer comprises a plurality of extension lines, and the coil structure surface layer is connected with the extension lines. The coil structure surface layer comprises a plurality of coils which are mutually sleeved, the extension line surface layer is formed by weaving air wrap yarn, and the air wrap yarn is woven through a first guide bar in a warp pile or warp oblique or cross over one-needle long extension line structure. The internal structure layer is formed by weaving elastic yarns or non-elastic yarns by adopting residual guide bars, the extension line surface layer forms a sanding effect surface, and the surface of the coil structure forms a flat surface layer. According to the utility model, the fabric production procedures are reduced, and fibers falling in the fabric use process can be reduced, so that the damage of micro plastics to human bodies and the environment is reduced.

Description

Technical Field

[0001] The utility model belongs to the technical field of textiles, and in particular relates to a high-quality, practical, sustainable and environmentally friendly warp knitted fabric capable of reducing the drop of microplastics. Background Art

[0002] Traditional warp-knitted fabrics often require the addition of pile yarns or special finishing processes such as hydro-milling, dry-milling, or fleecing to enhance warmth and comfort. However, this increases raw material costs, process complexity, production difficulty, and production waste.

[0003] In addition, after water grinding, dry grinding, and fleecing, the fabric fibers are damaged. After wearing or washing, tiny fibers will fall out, which will cause certain damage to the environment and the human body. Currently, synthetic fibers are commonly used in the warp knitting field, especially nylon and polyester. If these tiny fibers fall out, they will cause microplastic hazards, such as:

[0004] CN110141009A discloses a double-sided fleece-colored, seamless red bean velvet underwear set, the fabric of which is woven using a first-color spun yarn and a second-color spun yarn. The first-color spun yarn comprises cotton, Lenzing Modal, and Lycra fusible spandex, while the second-color spun yarn comprises Lenzing Modal and Lycra fusible spandex. The underwear set of this invention utilizes Lenzing Modal, a regenerated fiber that not only possesses the breathable and skin-friendly qualities of natural fibers but also has lower bending stiffness than cotton and a smooth surface, resulting in a soft, slick feel and a gentle sheen. The yarn is spun using a color-spinning process, making it durable and environmentally friendly, while also being durable and durable. The fabric is finished using a unique fleece-spinning-shearing process, resulting in a short, dense, soft, and uniform fleece.

[0005] CN116536836A discloses the technical field of clothing fabrics, and specifically relates to a single-faced small jacquard bottom fleece knitted fabric and a weaving method thereof. The weaving method provided by the present invention adopts the process of weaving the embryo - shaping the embryo cloth - pre-treatment - dyeing - post-treatment, color fixing - shaping, and through the improvement of the weaving process, combined with the characteristics of the yarn, and through the comprehensive application of the excellent properties of various fibers, a single-faced small jacquard bottom fleece knitted fabric is woven. After the fabric is subjected to a fleece shearing treatment during the post-dyeing finishing process, the overall thickness of the fabric is doubled while the weight remains unchanged. The bottom surface has a delicate velvety feel and is skin-friendly, which can effectively lock in air, store heat and keep warm, and give the fabric better wearing comfort. The single-faced small jacquard bottom fleece knitted fabric provided by the present invention has a fabric structure presenting a micro-texture mesh structure and a terry structure on the bottom surface, so that the entire fabric has excellent properties of being fluffy, storing heat and keeping warm, and providing a good wearing experience.

[0006] CN110983573A discloses a color-spun polyester-viscose fabric and a production method thereof. The fabric adopts four consecutive plucking steps during plucking and shearing, and the plucking is performed once for integrated molding, thereby improving production efficiency. A higher tension is used during the first plucking step to facilitate rapid plucking, while a lower tension is used during the second and third plucking steps to avoid damaging the fabric surface, thereby making the plucking hairs finer and more uniform. A higher tension is used during the fourth plucking step to comb out the plucking hairs for subsequent shearing. By controlling the tension during the four plucking steps, the plucking and shearing are uniform, resulting in a good wool-like effect, a fluffy and soft hand feel, resistance to pilling, and low shedding. The fabric has a good appearance after washing, is comfortable to wear, and has excellent antistatic properties. The method of the present invention has an advanced and reasonable processing flow and stable product quality. From the perspective of energy saving and environmental protection, the method is simple and reliable, has high productivity, a short cycle, a high color fixation rate, reduces sewage discharge, and can improve product quality, thereby achieving excellent quality and market economic benefits.

[0007] At the same time, the textile industry is also an energy-intensive industry. If one production process can be reduced, a lot of energy consumption can be reduced. Therefore, developing a warp-knitted fabric that reduces microplastics and is environmentally friendly has become a research hotspot in the field of textile technology. Summary of the Invention

[0008] In order to solve the above technical problems, the present invention provides an environmentally friendly warp knitted fabric, which reduces the fabric production process and can reduce the fibers dropped during the use of the fabric, thereby reducing the damage of microplastics to the human body and the environment.

[0009] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0010] An environmentally friendly warp-knitted fabric comprises a fabric body woven by a plurality of combs, the fabric body comprising an extension line surface layer, an internal structure layer and a coil structure surface layer, the internal structure layer being located inside the fabric body and connected to the extension line surface layer and the coil structure surface layer, the extension line surface layer comprising a plurality of extension lines, the coil structure surface layer comprising a plurality of coils intertwined with each other, the extension line surface layer being formed by weaving air-covered yarn, the air-covered yarn being woven by a first comb with a long extension line structure of warp pile or warp oblique or spanning more than one needle, the internal structure layer being woven by elastic yarn or non-elastic yarn using the remaining combs, the extension line surface layer being formed into a sanded effect surface, and the coil structure surface being formed into a flat surface layer.

[0011] As a further improvement, the air-covered yarn includes a core layer and an outer layer, the core layer is composed of elastic yarn, the outer layer is composed of non-elastic yarn, the core layer is spandex or elastic polyester, and the outer layer is nylon or polyester.

[0012] As a further improvement, the draft ratio of the elastic yarn of the air-covered yarn core layer is 1.5-4.0.

[0013] As a further improvement, in the air-covered yarn, the fineness of the elastic yarn constituting the core layer is 15D-140D, and the fineness of the non-elastic yarn constituting the outer layer is 15D-100D.

[0014] As a further improvement, the inner structural layer of the fabric body adopts non-elastic yarn with a fineness of 15D-150D, and elastic yarn with a fineness of 15D-480D.

[0015] As a further improvement, the comb bar of the extension line surface layer is woven in a motion mode with a yarn number of 1-0 / 2-3 / / or 1-0 / 3-4 / / or 1-0 / 1-1 / 1-2 / / or a crossing needle number greater than the ordinary warp flat 1-0 / 1-2 / / .

[0016] As a further improvement, the fabric body is woven in a full-thread, empty-thread or multi-thread manner.

[0017] As a further improvement, the core layer in the air-covered yarn is kept in a contracted state to tighten and shorten the extension line, and the non-elastic yarn as the outer layer forms an irregular arched structure to form a sanded effect surface.

[0018] As a further improvement, the sanded effect surface includes a plurality of raised yarns of different heights.

[0019] Compared with the prior art, the present invention has the following beneficial technical effects:

[0020] By using air-covered yarn in the warp knitting structure to achieve a self-brushed effect on the fabric, compared with the traditional hair effect obtained by water grinding, dry grinding, or even fleecing, the manufacturing cost is reduced, and no additional special finishing process is required to make the hair effect, which greatly reduces the production cost; the production efficiency is improved, because there is no need for sanding or fleecing processes, the production time is greatly shortened; the function of the textile is optimized: the comfort, warmth and aesthetics of the textile are improved, and the fibers dropped during the use of the fabric are reduced, thereby reducing the damage of microplastics to the human body and the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the structure of the utility model. DETAILED DESCRIPTION

[0022] The embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and are not to be construed as limiting the present invention.

[0023] In the description of the present invention, it should be understood that if the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like are used to indicate the orientation or position relationship based on the orientation or position relationship shown in the accompanying drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0024] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, removable connections, or integral connections. They may refer to mechanical connections or electrical connections. They may refer to direct connections or indirect connections through an intermediary, and they may refer to internal communication between two components or interactions between two components. Those skilled in the art will understand the specific meanings of these terms in the present invention based on the specific circumstances.

[0025] refer to Figure 1 As shown, a microplastic-reducing, environmentally friendly warp-knitted fabric comprises a fabric body woven using several combs. The fabric body comprises a stretching line surface layer 1, an internal structure layer, and a coil structure surface layer 2. The internal structure layer is located within the fabric body and connected to the stretching line surface layer and the coil structure surface layer. The stretching line surface layer comprises several stretching lines 3, and the coil structure surface layer comprises several coils 4 intertwined with each other. The stretching line surface layer is woven using air-encased yarn, which is woven using a first comb with a long stretching line structure that is warp pile, warp diagonal, or spans more than one stitch. The internal structure layer is woven using elastic or non-elastic yarn using the remaining combs. The stretching line surface layer is formed into a sanded surface, and the coil structure surface is formed into a smooth surface layer. The use of air-encased yarn creates a naturally sanded effect on the fabric body surface, eliminating the need for additional special finishing processes such as water grinding, dry grinding, or even plucking, thus saving manufacturing steps and improving production efficiency. Microplastics refer to microplastics. The extended line surface layer serves as the surface layer of the fabric body, and the coil structure surface layer serves as the bottom layer of the fabric body.

[0026] The air-covered yarn comprises a core layer and an outer layer. The core layer is made of elastic yarn, while the outer layer is made of inelastic yarn. The core layer is made of spandex or elastic polyester, while the outer layer is made of nylon or polyester. During production, the inelastic yarn (the outer layer) and the elastic yarn (the core layer) are simultaneously drawn through a pre-set nozzle. Highly compressed air is then applied regularly to form a rhythmic network of yarn dots. The inelastic yarn herein includes yarn with very little elasticity or non-elastic yarn.

[0027] Nylon fiber, also known as polyamide fiber, is more abrasion-resistant than all other fibers, 10 times more abrasion-resistant than cotton and 20 times more abrasion-resistant than wool. When stretched to 3-6%, its elastic recovery rate can reach 100%. It can withstand tens of thousands of flexings without breaking and has excellent fatigue resistance.

[0028] Spandex fiber is the abbreviation of polyurethane elastic fiber, generally written as PU. It is a block copolymer whose long copolymer chain consists of soft segments and hard segments.

[0029] Spandex usually has an elongation of 400% to 800% and excellent elastic recovery performance. When it is elongated by 50%, the shrinkage rate even exceeds 99%.

[0030] In this embodiment, the core layer of the air covered yarn is made of spandex, and the outer layer is made of nylon. The fineness of the spandex is 15D-140D, the fineness of the nylon is 15D-100D, and the spandex draft ratio is 1.5-4.0.

[0031] When the internal structural layer of the fabric body adopts non-elastic yarn, the fineness of the non-elastic yarn is 15D-150D, and a nearly inelastic layer is formed inside the fabric body; when the internal structural layer adopts elastic yarn, the fineness of the elastic yarn is 15D-480D, and an elastic layer is formed inside the fabric body.

[0032] The fabric body is woven using multiple comb bars, of which the first comb bar is used to weave the extension line surface layer, and the remaining comb bars are used to weave the internal structure layer of the fabric body. Specifically, comb bar GB1 is woven through air-covered yarn using a long extension line structure weaving method with warp pile or warp bias or spanning more than one needle to form the surface of the fabric body, thereby obtaining an extension line surface layer and a coil structure surface layer. The remaining comb bars GB2, GB3, etc. are woven using a preset organizational structure to form the internal structure layer of the fabric body, thereby obtaining an environmentally friendly warp knitted fabric that reduces microplastics. Comb bar GB1 is woven using a movement method with a yarn pad number of 1-0 / 2-3 / / or 1-0 / 3-4 / / or 1-0 / 1-1 / 1-2 / / or with a span number greater than the ordinary warp flat 1-0 / 1-2 / / , while the other comb bars can be woven using other yarn pad numbers as needed.

[0033] As for the yarn threading method, full threading, empty threading or multiple threading methods can be used for weaving.

[0034] In air-wrapped yarns, the stretched elastic yarn in the core layer exerts a tightening force, causing the warp-knitted fabric to shrink, forming a high-density warp-knitted fabric. Because the elastic yarn in the core layer has a certain stretch factor, it maintains its shape during shrinkage, while the non-elastic yarn in the outer layer will bulge irregularly during the shrinkage of the fabric.

[0035] The fabric surface of the warp pile flat structure is characterized by long extension lines on the surface and interlocking loops on the base. As the woven fabric shrinks, the extension lines on the surface shorten, and the non-elastic yarns on the outer layer of the air-wrapped yarn will bulge irregularly, forming a fuzzy surface. The loops on the base tighten to form a relatively flat surface. The result is a warp knitted fabric with a natural fleece effect on one side and a flat surface on the other.

[0036] Example 1

[0037] Yarn used: PA6 40D / 24F / 1FD DTY empty PU 20D (PU draft 3.5);

[0038] PU 30D / 2F SD (PU draft 1.6);

[0039] Yarn warping machine used for warp knitting: Karl Mayer DS21 / 30NC-2;

[0040] Filament warping: negative yarn feeding;

[0041] Warping temperature: 25℃; Warping humidity: 65%;

[0042] Spandex warping: positive yarn feeding;

[0043] Warping temperature: 25℃; Warping humidity: 65%;

[0044] The warp knitting machine used is Karl Mayer HKS2-3E.

[0045] Weaving process: GB1 yarn PA6 40D / 24F / 1FD DTY empty PU 20D draft 3.5, knitted with a lapping number of 1-0 / 2-3 / / and a full draw-in. GB2 yarn: Spandex 30D / 2F SD, knitted with a lapping number of 1-2 / 1-0 / / and a full draw-in.

[0046] Finishing process: washing - pre-dyeing - finishing - cloth inspection.

[0047] Finished fabric style: One side of the fabric is fleecy, soft and comfortable, while the other side is smooth and clean, suitable for the front side of clothing.

[0048] Test results:

[0049] Specifications: width 152cm; weight 200g / ㎡;

[0050] LTD03 7.5 lbf tensile test: warp opening 150%; weft opening 100%;

[0051] BS 8479-2008,2000revolutions snagging test:

[0052] The capillary effect surface is level 2.5 in the warp direction and level 3.0 in the weft direction, and the flat surface is level 4.0 in the warp direction and level 3.0 in the weft direction.

[0053] ASTM D3512 / D3512M-2016, 30 minutes pilling test:

[0054] Hair effect surface: 4.5 level; Flat surface: 4.5 level;

[0055] GB / T 18319-2019, Warm up 5 minutes warmth retention test:

[0056] Maximum temperature rise: 7.96°C; average temperature rise: 4.86°C, final test result: Pass;

[0057] Appearance test after washing: ATCC 135, 1III A(ii), 5 cycles, 15 cycles, 25 cycles: test result: grade 4.5.

[0058] Hair effect feel test FZ / T01166-2022 (FTT): To illustrate that this design fabric has its own hair effect, a similar-hair-effect brushed fabric and a similar-hair-effect fleece fabric were tested together with this design fabric in the FTT test. The subjective indicators such as smoothness, softness, and warmth were comprehensively compared. The results are shown in Table 1.

[0059] Table 1

[0060] sample Average value of comprehensive subjective indicators This design fabric 0.54 Brushed fabric with a wool-like effect 0.50 Fleece fabric with a hair-like effect 0.55

[0061] As shown in Table 1, the hand feel and fleece effect of the designed fabric can basically reach the same level as traditional sanded or fleece fabrics.

[0062] Fiber loss test method 1: Based on the fabrics listed in Table 1, use the ISO 6330:1994 test method. Take the same area of ​​fabric and weigh each piece dry. Then, wash them all in a washing machine at 60°C for 60 minutes. Finally, remove the fabrics and weigh them dry again. Subtract the post-wash weight from the pre-wash weight, then divide by the pre-wash weight to calculate the percentage of weight loss. This determines fiber loss. The results are shown in Table 2.

[0063] Table 2

[0064] sample Weight loss percentage (%) Whether fiber is lost This design fabric 0.00 no Brushed fabric with a wool-like effect 0.09 yes Fleece fabric with a hair-like effect 0.37 yes

[0065] Fiber loss test method 2: Take the same area of ​​fabric and seal the edges with glue (to prevent broken fibers from falling and affecting the test). Place the samples in beakers equipped with magnetic rotors and spin them for 60 minutes with an equal amount of clean water. Then, pour the water from the beakers onto filter paper and observe for fibers. The results are shown in Table 3.

[0066] Table 3

[0067] sample Observe filter paper Whether fiber is lost This design fabric No accumulated fiber no Brushed fabric with a wool-like effect Accumulated fiber yes Fleece fabric with a hair-like effect Accumulated fiber yes

[0068] As can be seen from Tables 2 and 3, the fabric of this design does not shed fibers after washing.

[0069] This patented utility model successfully develops a microplastic-reducing, eco-friendly warp knitted fabric by using air-encased yarn containing spandex in its warp knitting structure. This fabric offers a comfortable feel and excellent warmth retention, while also ensuring excellent snagging and pilling resistance, resulting in a higher-quality fabric. Because it eliminates the need for traditional finishing processes like sanding or fleecing to create a fleecy effect, the fabric reduces microplastics and eliminates fiber shedding, contributing to environmental and human health benefits. By eliminating these finishing processes, the fabric reduces manufacturing costs and improves production efficiency.

[0070] It should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent replacements for some of the technical features therein. However, any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An environmentally friendly warp knitted fabric, comprising a fabric body woven by a plurality of comb bars, characterized in that: The fabric body includes an extension line surface layer, an internal structure layer and a coil structure surface layer. The internal structure layer is located inside the fabric body and is connected to the extension line surface layer and the coil structure surface layer. The extension line surface layer includes a plurality of extension lines, and the coil structure surface layer includes a plurality of coils that are intertwined with each other. The extension line surface layer is formed by weaving air-covered yarn. The air-covered yarn is woven with a first comb with a long extension line structure of warp velvet or warp oblique or spanning more than one needle. The internal structure layer is woven with elastic yarn or non-elastic yarn using the remaining combs. The extension line surface layer is formed into a sanded effect surface, and the coil structure surface is formed into a flat surface layer.

2. The environmentally friendly warp knitted fabric according to claim 1, characterized in that: The air-covered yarn comprises a core layer and an outer layer, wherein the core layer is made of elastic yarn and the outer layer is made of non-elastic yarn. The core layer is spandex or elastic polyester and the outer layer is nylon or polyester.

3. The environmentally friendly warp knitted fabric according to claim 2, characterized in that: The drafting ratio of the core layer in the air covered yarn is 1.5-4.

0.

4. The environmentally friendly warp knitted fabric according to claim 2, characterized in that: In the air-covered yarn, the fineness of the elastic yarn constituting the core layer is 15D-140D, and the fineness of the non-elastic yarn constituting the outer layer is 15D-100D.

5. The environmentally friendly warp knitted fabric according to claim 1, characterized in that: The inner structural layer of the fabric body adopts non-elastic yarn with a fineness of 15D-150D, and elastic yarn with a fineness of 15D-480D.

6. The environmentally friendly warp knitted fabric according to claim 1, characterized in that: The comb bar of the extension line surface layer is woven in a motion mode with a yarn number of 1-0 / 2-3 / / or 1-0 / 3-4 / / or 1-0 / 1-1 / 1-2 / / or a crossing needle number greater than that of ordinary warp flat 1-0 / 1-2 / / .

7. The environmentally friendly warp knitted fabric according to claim 1, characterized in that: The fabric body is woven in a full-thread, empty-thread or multi-thread manner.

8. The environmentally friendly warp knitted fabric according to claim 1, characterized in that: The core layer in the air-covered yarn is kept in a contracted state to tighten and shorten the extension line, and the non-elastic yarn as the outer layer forms an irregular arched structure to form a sanded effect surface.

9. The environmentally friendly warp knitted fabric according to claim 8, characterized in that: The sanded effect surface comprises a plurality of raised yarns of different heights.

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