Freely cut knit fabric and manufacturing method

Abstract

This invention provides a knit fabric that can be freely cut and a method for manufacturing it. [Solution] The freely cut knit fabric has a double-sided flat knit air layer structure, and the knit pattern of the above freely cut knit fabric consists of 6 courses of pattern in one cycle, and the 6 courses of pattern are as follows: the first course is float, tuck, tuck, float, the second and fifth courses are knit, knit, float, float, the third and sixth courses are float, float, knit, knit, and the fourth course is tuck, float, float, tuck. [Effects] Compared to conventional technology, the knit fabric of the present invention has a special structural design and knitting pattern that interact and work synergistically to greatly improve the fabric's ability to curl, fray, and shed threads, meeting customer demands for free cutting, while simultaneously ensuring the fabric's pleasant feel and flexibility.

Description

Technical Field

[0001] The present invention relates to the field of knitted fabrics, and specifically to a knitted fabric that can be freely cut and a manufacturing method thereof.

Background Art

[0002] With the development of society, people's requirements for underwear are increasing from basic wearing needs to requirements such as special functionality and fashionability. Although conventional elastic underwear fabrics are recognized by people in terms of fit, the edges of elastic fabrics are likely to roll up, and hemming is required during cutting.

[0003] However, hemming not only consumes materials and labor, but often also affects the comfort during wearing. Clothing made of such fabrics leaves marks of the clothing on the body when worn, damaging the aesthetics.

[0004] In the prior art, the patent with application number CN202410480628.X according to Patent Document 1 discloses a horizontal knitted freely cut fabric and a manufacturing method. The fabric includes an air layer jacquard structure, which includes three layers: a bottom layer, an intermediate layer, and a surface layer. The bottom layer is located below the intermediate layer, the surface layer is located above the intermediate layer. The bottom layer is woven with nylon yarn and ordinary spandex, the intermediate layer is connected with ordinary spandex and extends to the surface layer, and the surface layer is woven with nylon yarn and ordinary spandex. This patent can achieve the effect of making the fabric less likely to fray to a certain extent and suppressing the fluffing and rolling up of the untreated ends, but the improvement in the rolling up property, fraying property, and yarn slipping property of the fabric is limited, and the flexibility of the fabric is not sufficient either.

[0005] The present invention has been made in view of these.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

[0007] The objective of the present invention is to propose a knit fabric that can be freely cut and a manufacturing method that solves the problems of conventional technology, which have insufficient improvements in terms of fabric curling, fraying, and thread shedding, as well as the poor flexibility of the fabric. [Means for solving the problem]

[0008] To achieve the above objective, the technical proposal of the present invention is implemented as follows.

[0009] A knit fabric that can be freely cut, wherein the above-mentioned freely cut knit fabric has a double-sided flat knit air layer structure, The knit pattern of the above freely cut knit fabric consists of 6 courses of patterns per cycle, and the patterns of the 6 courses are as follows: The first course is float, tuck, tuck, float. The second and fifth courses are knit, knit, float, float. The third and sixth courses are float, float, knit, knit. The fourth course is tuck, float, float, tuck.

[0010] Furthermore, the above-mentioned freely cut knit fabric includes a surface layer, an intermediate layer, and a back layer in order from the outside to the inside, and the surface layer and the back layer are connected via the intermediate layer.

[0011] Furthermore, in the above-mentioned freely cut knit fabric, the horizontal mesh / inch × vertical mesh / inch ratio is 3000 or more.

[0012] Furthermore, the first and fourth courses mentioned above are the yarns of the middle layer, the second and fifth courses mentioned above are the yarns of the back layer, and the third and sixth courses mentioned above are the yarns of the surface layer.

[0013] Furthermore, the surface and back layers of the yarn include a first yarn and a second yarn, the first yarn being a polyester filament, a polyamide filament, or an artificial filament, the second yarn being an elastic filament, and the intermediate layer yarn being an elastic filament.

[0014] Furthermore, the thread thickness of the polyester filament, polyamide filament, and artificial filament mentioned above is 15-55D, and the thread thickness of the elastic filament mentioned above is 15-30D.

[0015] Furthermore, the yarn length of the polyester filament, polyamide filament, and artificial filament yarns is 20-25 cm / 100 needles, and the yarn length of the elastic filament yarn is 8-12 cm / 100 needles.

[0016] Furthermore, the above-mentioned freely cut knit fabric has a knitting structure with two needle paths on the upper dial and two needle paths on the lower cylinder.

[0017] A second aspect of the present invention proposes a method for manufacturing a freely cut knit fabric, the method for manufacturing a freely cut knit fabric being used to manufacture the freely cut knit fabric described in any one of the present inventions, the method for manufacturing a freely cut knit fabric being used in the following steps, namely, S1, preparing the thread, S2, raw fabric weaving, S3, dyeing of raw fabric, S4 includes fabric finishing treatment.

[0018] Furthermore, in step S3, the staining of the raw material is carried out in the following steps, namely, S31, Pre-treatment, S32, staining, S33, including the tank discharge.

[0019] Furthermore, in step S4, the finishing process of the fabric includes the following steps, namely, S41, softening treatment, S42, drying, S43, shape fixation by a stenter.

Advantages of the Invention

[0020] Compared with the prior art, the freely cuttable knitted fabric and manufacturing method described in the present invention have the following advantageous effects.

[0021] In the freely cuttable knitted fabric and manufacturing method described in the present invention, the double-sided horizontal knitting air layer structure, knitting pattern, triangular arrangement, and manufacturing method are related to each other and act synergistically, thereby significantly improving the fabric's curling property, fraying property, and yarn pulling-out property, meeting the customer's requirements for free cutting. At the same time, the good touch and flexibility of the fabric are ensured. Furthermore, the three-dimensional feeling and elasticity of the fabric are also improved.

Brief Description of the Drawings

[0022] [Figure 1] It is a schematic diagram of the triangular arrangement of the freely cuttable knitted fabric described in the embodiment of the present invention. [Figure 2] It is a schematic diagram of the knitting arrangement of the freely cuttable knitted fabric described in the embodiment of the present invention. [Figure 3] It is a schematic diagram of the structure of the freely cuttable knitted fabric described in the embodiment of the present invention.

[0023] Explanation of Reference Signs 11, surface layer, 111, first main layer, 112, first core layer, 12, back layer, 121, second main layer, 122, second core layer, 2, intermediate layer (connecting yarn), A, first knitting needle, B, second knitting needle, C, third knitting needle, D, fourth knitting needle.

Modes for Carrying Out the Invention

[0024] To the extent that there is no contradiction, the embodiments and features of the embodiments of the present invention can be combined with each other. In the embodiments of the present invention, descriptions such as "First," "Second," etc., are used for explanatory purposes only and should not be understood as indicating or implying their relative importance or implicitly indicating the number of technical features shown. Accordingly, features limited by "First" or "Second" may explicitly or implicitly include at least one such feature. While the technical ideas between each embodiment can be combined with each other, they must be implementable by a person skilled in the art, and if a combination of technical ideas is contradictory or unimplementable, such a combination of technical ideas should be considered nonexistent and not within the scope of protection claimed by the present invention.

[0025] The present invention will be described in detail below with reference to the drawings, in accordance with the embodiments.

[0026] Example 1 As shown in Figures 1-3, this embodiment proposes a knit fabric that can be freely cut. This knit fabric has a double-sided flat-knit air layer structure, which provides the fabric with lightweight and breathable properties. The knit pattern of this knit fabric consists of 6 courses of pattern per cycle, and the 6 courses of pattern are as follows: The first course is float, tuck, tuck, float. The second and fifth courses are knit, knit, float, float. The third and sixth courses are float, float, knit, knit. The fourth course was tuck, float, float, tuck.

[0027] This unique pattern design not only enhances the fabric's three-dimensionality and elasticity, but also reduces fraying and curling during cutting.

[0028] Specifically, the above-mentioned freely cut knitted fabric has a sandwich weave structure, comprising a surface layer 11, an intermediate layer 2, and a backing layer 12 in order from the outside to the inside, with the surface layer 11 and the backing layer 12 connected via the intermediate layer 2. These three layers are interconnected using a special knitting method, forming an integrated structure that combines stability and elasticity.

[0029] Specifically, in order to meet the density requirements for the fabric, the above-mentioned freely cut knit fabric had a horizontal mesh / inch × vertical mesh / inch ratio of 3000 or more, that is, the product of the horizontal mesh / inch and the vertical mesh / inch ratio was 3000 or more.

[0030] Of these, horizontal mesh / inch indicates the number of horizontal meshes per inch of length, and vertical mesh / inch indicates the number of vertical meshes per inch of length.

[0031] Thanks to its high-density design, the fabric is denser and more abrasion-resistant, while maintaining excellent breathability and flexibility.

[0032] Specifically, the first and fourth courses were yarns of the intermediate layer 2, the second and fifth courses were yarns of the back layer 12, and the third and sixth courses were yarns of the surface layer 11.

[0033] Specifically, the yarns of the surface layer 11 and the back layer 12 include a first yarn and a second yarn, the first yarn being a polyester filament, a polyamide filament, or an artificial filament, the second yarn being an elastic filament that ensures the strength of the fabric and imparts a certain degree of elasticity to the fabric, and the yarns of the intermediate layer 2 being elastic filaments that further improve the stretchability and resilience of the fabric.

[0034] The above-mentioned elastic filament can be stretched to more than twice its original length, further improving the adaptability and comfort of the fabric.

[0035] In this embodiment, the yarn of the surface layer 11 and the yarn of the back layer 12 were polyester filaments and elastic filaments, respectively.

[0036] More specifically, as shown in Figure 3, the surface layer 11 includes a first main layer 111 and a first interlining layer 112. The first main layer 111 is located near the outer surface of the fabric, the yarn of the first main layer 111 is polyester filament, and the yarn of the first interlining layer 112 is elastic filament. The back layer 12 includes a second main layer 121 and a second interlining layer 122. The second main layer 121 is located near the inner surface of the fabric, the yarn of the second main layer 121 is polyester filament, and the yarn of the second interlining layer 122 is elastic filament.

[0037] The surface layer 11 and back layer 12 of the above-mentioned freely cut knit fabric both use 15D-55D denier polyester or polyamide filament as the main layer, and elastic filament that can be stretched to more than twice its original length as the core layer, and the intermediate layer 2 uses elastic filament that can be stretched to more than twice its original length as the connecting yarn. As a result, the fabric's ability to curl, fray, and shed threads is greatly improved, meeting customer requirements for free cutting, while simultaneously ensuring the fabric's pleasant feel and flexibility, making it very suitable for manufacturing clothing that comes into direct contact with the skin, such as underwear.

[0038] More specifically, the elastic filament mentioned above was spandex.

[0039] Specifically, the thickness of the polyester filament thread was 40D, and the thickness of the elastic filament thread was 20D.

[0040] Specifically, the yarn length of the polyester filament yarn was 22 cm / 100 needles, and the yarn length of the elastic filament yarn was 10 cm / 100 needles.

[0041] Specifically, as shown in Figures 1 and 2, the above-mentioned freely cut knit fabric had a knitting structure with two needle paths on the upper dial and two needle paths on the lower cylinder.

[0042] More specifically, the first knitting needle A and the second knitting needle B are placed on the upper dial, and the third knitting needle C and the fourth knitting needle D are placed on the lower cylinder. In the first course, the second knitting needle B and the third knitting needle C perform a tuck operation. In the second and fifth courses, the first knitting needle A and the second knitting needle B perform a knit operation. In the third and sixth courses, the third knitting needle C and the fourth knitting needle D perform a knit operation. In the fourth course, the first knitting needle A and the fourth knitting needle D perform a tuck operation.

[0043] In this embodiment, a method for manufacturing a freely cut knit fabric is further proposed, and the above method for manufacturing a freely cut knit fabric is used to manufacture the freely cut knit fabric described in any one of the above, and the above method for manufacturing a freely cut knit fabric is the following step, namely, S1, preparing the thread, S2, raw fabric weaving, S3, dyeing of raw fabric, S4 includes fabric finishing treatment.

[0044] Specifically, in step S3, the staining of the raw material included the following steps: S31, pretreatment; S32, staining; and S33, unloading.

[0045] In step S31, the pretreatment involved sequentially performing ultrasonic primary treatment, boiling bleaching treatment, and ultrasonic secondary treatment on the raw dough.

[0046] Specifically, the primary ultrasonic treatment included the following steps: ultrasonic treatment in cooperation with cellulase to allow ultrasound to penetrate deeply into the fiber, with an ultrasonic frequency of 80 kHz, a cellulase concentration of 8% (owf) to maintain cellulase activity, a treatment temperature of 40°C, a pH of 6 to optimize the cellulase's operating environment, and a treatment time of 40 minutes to ensure the treatment effect.

[0047] In the initial ultrasonic treatment process, ultrasonic treatment was performed in cooperation with cellulase. By utilizing the cavitation effect of ultrasound and the catalytic action of cellulase, impurities on the surface of the raw material and adhesive substances between fibers were removed, improving the hygroscopicity of the fibers and preparing them for the subsequent dyeing process.

[0048] By using ultrasonic primary treatment to thoroughly remove fibers of varying lengths from the fiber surface, the fibers within the fabric become softer, giving the fabric a relatively superior luster and smoothness. Simultaneously, the vibrational action of the ultrasound loosens and tidies up the fibers in the fabric, making the fabric more voluminous, softer, and smoother. The etching action of the ultrasonic treatment causes a certain degree of destructiveness to the fibers on the woven raw fabric, contributing to the release of fibers within the tissue and the adsorption of softener during the boiling bleaching process.

[0049] Specifically, the boiling bleaching treatment involved placing the raw material into a bath solution, adding the following boiling bleaching formula to the bath solution: 2 g / L of purified enzyme, 0.2 g / L of alkali, 2 g / L of H2O, 2 g / L of surfactant, 1 g / L of wrinkle inhibitor, and 3 g / L of softener. Then, the bath solution containing the above boiling bleaching formula was heated to 80°C and kept warm for 20 minutes.

[0050] By using a rational and mild boiling bleaching formula, impurities, waxy substances, ash, and cottonseed husks are removed from the fabric fibers, while minimizing wear on the fabric fibers themselves. This maximizes the profitability of the fabric and avoids the impact on performance such as fabric fastness due to excessive fiber wear.

[0051] By performing the boiling bleaching treatment, firstly, wear and tear on the fabric itself is minimized; secondly, it is advantageous for the efficiency and colorfastness of subsequent dyeing of the fabric; thirdly, it is advantageous for increasing the flexibility of the fabric; and fourthly, the fabric's ability to curl, fray, and shed threads is improved, thus meeting the customer's requirement for free cutting.

[0052] The ultrasonic secondary treatment involved washing the boiled and bleached raw material twice with water, adding a reducing agent solution during the washing, and then performing ultrasonic treatment at 40°C for 15 minutes with a bath ratio of 1:10 and an ultrasonic frequency of 90kHz. After the second ultrasonic treatment, polyvinyl alcohol was added, and the material was held at room temperature for 10 minutes before being washed with water and dried.

[0053] The etching effect of the ultrasonic secondary treatment caused a certain degree of destructiveness to the fibers on the woven fabric, contributing to the release of fibers within the tissue and the adsorption of softener in subsequent processes.

[0054] Firstly, the fabric's ability to curl, fray, and shed threads has been improved, meeting the customer's requirement for free cutting. Secondly, the fabric has been given relatively good flexibility.

[0055] In step S31, the raw fabric is subjected to primary ultrasonic treatment, boiling bleaching treatment, and secondary ultrasonic treatment in sequence. The three treatments—primary ultrasonic treatment, boiling bleaching treatment, and secondary ultrasonic treatment—are interconnected and act synergistically, which is advantageous in firstly increasing the flexibility of the fabric, secondly improving the fabric's ability to curl, fray, and detach threads, thus meeting the customer's requirement for free cutting, and thirdly improving the efficiency and colorfastness of subsequent dyeing of the fabric.

[0056] Specifically, in step S4, the finishing treatment of the fabric included the following steps: S41, softening treatment; S42, drying; and S43, shape fixing with a stent.

[0057] Specifically, in step S43, the temperature during shape fixing by the stent was 130-170°C.

[0058] Example 2 In this embodiment, the difference from Embodiment 1 is that Specifically, the thickness of the polyester filament thread was 55D, and the thickness of the elastic filament thread was 30D. Specifically, the yarn length of the polyester filament yarn was 20 cm / 100 needles, and the yarn length of the elastic filament yarn was 12 cm / 100 needles.

[0059] Example 3 In this embodiment, the difference from Embodiment 1 is that Specifically, the thickness of the polyester filament thread was 15D, and the thickness of the elastic filament thread was 15D. Specifically, the yarn length of the polyester filament yarn was 25 cm / 100 needles, and the yarn length of the elastic filament yarn was 8 cm / 100 needles.

[0060] Example 4 In this embodiment, the difference from Embodiment 1 is that the yarns of the surface layer 11 and the back layer 12 were polyamide filaments and elastic filaments. The threads of the first main layer 111 and the second main layer 121 described above were polyamide filaments. Specifically, the thickness of the polyamide filament thread was 40D. Specifically, the length of the polyamide filament thread described above was 22 cm per 100 stitches.

[0061] Example 5 In this embodiment, the difference from Embodiment 1 is that the yarns of the surface layer 11 and the back layer 12 were polyamide filaments and elastic filaments. The threads of the first main layer 111 and the second main layer 121 described above were polyamide filaments. Specifically, the thickness of the polyamide filament thread was 55D. Specifically, the length of the polyamide filament thread described above was 20 cm per 100 stitches.

[0062] Example 6 In this embodiment, the difference from Embodiment 1 is that the threads of the surface layer 11 and the back layer 12 were artificial filaments and elastic filaments. The threads of the first main layer 111 and the second main layer 121 described above were artificial filaments. Specifically, the thickness of the artificial filament thread mentioned above was 15D. Specifically, the length of the artificial filament thread described above was 25 cm per 100 stitches.

[0063] Comparative Example 1 In this proportional representation, the difference from Example 1 is that it uses the triangular arrangement and organizational structure in the embodiment for carrying out the invention of the patent application number CN202410480628.X related to Patent Document 1. Specifically, unlike Example 1, the raw fabric was manufactured using a double-sided circular knitting machine during the fabric knitting process. The dial needle setting on the double-sided circular knitting machine was BABABABA, and the cylinder needle setting was ABABABAC. A double needle position was used. Here, in the first course, the dial first track needle A is float and the second track needle B is tuck; in the cylinder, the first track needle A is float, the second track needle B is knit and the third track needle C is tuck, and normally spandex is put into the first course; The second course uses knitting needles A and B on the first and second tracks of the dial; and knitting needles A, B, and C on the first, second, and third tracks of the cylinder; and the second course is used for nylon and regular spandex; The third course has the first and second track knitting needles A and B floating; the first, second, and third track knitting needles A, B, and C knitting; and the third course is filled with nylon and regular spandex; In the fourth course, the first track needle A is tucked and the second track needle B is floated; in the cylinder, the first track needle A is tucked and the second and third track needles B and C are floated, and the fourth course is normally filled with spandex; Courses 5, 8, 11, 14, and 17 are knitted using the same method as course 2; Courses 6, 9, 12, 15, and 18 are knitted in the same way as course 3; Courses 10 and 16 are knitted in the same way as course 4; The seventh course uses the same knitting technique as the first course; In the 13th course, the first track needle A of the dial is floating, and the second track needle B is tucked; in the cylinder, the first track needle A is floating, and the second and third track needles B and C are tucked, and spandex is normally added to the 13th course; One cycle consists of courses 1 through 18, and the raw fabric was knitted in this manner.

[0064] Performance testing For the fabrics obtained in Examples 1-6 and Comparative Example 1, flexibility tests and evaluations of curling, fraying, and thread shedding were conducted on 100 consumers. The average scores for flexibility tests and curling are shown in Table 1. [Table 1]

[0065] As can be seen from Table 1, the freely cut knit fabrics described in Examples 1 to 6 of the present invention have significantly improved winding, fraying, and thread shedding properties due to the interrelationship and synergistic effects of the double-sided flat-knit air layer structure, knitting pattern, triangular arrangement, and manufacturing method, thereby meeting customer demands for free cutting, while simultaneously ensuring the fabric's pleasant feel and flexibility.

[0066] Although the present invention is disclosed as described above, it is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention, and therefore the claims of the present invention are equivalent to those limited to the patent claims.

Claims

1. A knit fabric that can be freely cut, wherein the freely cut knit fabric has a double-sided flat knit air layer structure, and the knit pattern of the freely cut knit fabric consists of a cycle of 6 courses, the 6 courses of patterns being as follows: The first course is float, tuck, tuck, float. The second and fifth courses are knit, knit, float, float. The third and sixth courses are float, float, knit, knit. The fourth course is characterized by tuck, float, float, tuck. A knit fabric that can be freely cut.

2. The aforementioned freely cut knit fabric includes, in order from the outside to the inside, a surface layer (11), an intermediate layer (2), and a back layer (12), and the surface layer (11) and the back layer (12) are connected via the intermediate layer (2), characterized in that The freely cut knit fabric according to claim 1.

3. The knit fabric that can be freely cut is characterized in that the horizontal mesh / inch × vertical mesh / inch is 3000 or more. The freely cut knit fabric according to claim 2.

4. The first course and the fourth course are yarns of the intermediate layer (2), the second course and the fifth course are yarns of the back layer (12), and the third course and the sixth course are yarns of the surface layer (11), characterized in that The freely cut knit fabric according to claim 3.

5. The yarn of the surface layer (11) and the yarn of the back layer (12) include a first yarn and a second yarn, wherein the first yarn is a polyester filament, a polyamide filament, or an artificial filament, the second yarn is an elastic filament, and the yarn of the intermediate layer (2) is an elastic filament. The freely cut knit fabric according to claim 4.

6. The thickness of the polyester filament, polyamide filament, and artificial filament threads is 15 to 55D, and the thickness of the elastic filament threads is 15 to 30D, characterized in that The freely cut knit fabric according to claim 5.

7. The yarn length of the polyester filament, polyamide filament, and artificial filament is 20 to 25 cm / 100 needles, and the yarn length of the elastic filament is 8 to 12 cm / 100 needles, characterized in that The freely cut knit fabric according to claim 6.

8. The aforementioned freely cut knit fabric is characterized by having a knitting structure with two needle paths on the upper dial and two needle paths on the lower cylinder. The freely cut knit fabric according to claim 1.

9. A method for manufacturing a knit fabric that can be freely cut, wherein the method for manufacturing a knit fabric that can be freely cut is used to manufacture a knit fabric that can be freely cut according to any one of claims 1 to 8, and the method for manufacturing a knit fabric that can be freely cut comprises the following steps, namely, S1. Preparation of the thread, S2, raw fabric weaving, S3, dyeing of raw fabric, S4, a finishing treatment of the fabric, is a characteristic feature. A method for manufacturing knit fabric that can be freely cut.

10. In step S3, the staining of the raw fabric is carried out in the following steps, namely, S31, Pre-treatment, S32, staining, Features include S33, dispensing, A method for manufacturing a knit fabric that can be freely cut, as described in claim 9.

11. In step S4, the finishing process of the fabric is carried out in the following steps, namely, S41, Flexible processing, S42, drying, S43, characterized by including shape fixing by a stent, A method for manufacturing a knit fabric that can be freely cut, as described in claim 9.

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