Flat elastic Anti-curling warp-knitted short fiber fabric

Abstract

A flat elastic anti-curling warp-knitted short fiber fabric, comprising a fabric body. The fabric body is formed by knitting at least two types of yarns, including elastic yarns and non-elastic short fiber yarns; the short fiber yarns have a fineness ranging from 50 denier to 180 denier; the elastic yarns are knitted in the fabric body to form open loops; in each open loop, there are no cross-over points at the base of an underlap; all or some of the short fiber yarns and the elastic yarns are arranged in the same direction during knitting; a flat elastic layer is formed on the fabric body; and a fabric touch tester is used to perform a test to obtain an SDLAtlas standard wherein the surface roughness amplitude (SRA) of front and back surfaces is less than or equal to 40 µm.

Description

A smooth, elastic and anti-curling warp-knitted staple fiber fabric Technical Field

[0001] The invention relates to the field of textile clothing fabrics, in particular to a smooth, elastic and anti-curling warp-knitted staple fabric. Background Art

[0002] Garment fabrics have advantages such as no curling, no unraveling, and no frayed edges, and can be defined as free-cut fabrics among knitted fabrics. Free-cut fabrics offer advantages in terms of cutting, sewing, and fabric loss, such as freedom in direction and shape, no need for hemming, and maximum fabric utilization, making them comfortable to wear. However, polyester fabrics have poor dyeing properties and poor hygroscopicity; nylon fabrics are prone to static electricity and have poor water absorption; and staple fiber fabrics are increasingly in demand due to their softness, skin-friendliness, good hygroscopicity, warmth, and breathability. However, the unstable strength, short spinning length, and high twist of staple fibers make them difficult to weave in warp knitting. To better meet these needs, this patent selects yarns, combines staple fiber yarns with elastic yarns, and adjusts the weaving and finishing processes. While ensuring a smooth, lustrous, and soft hand, this fabric exhibits advantages such as no curling, no unraveling, high elasticity, good hygroscopicity, antistatic properties, and good breathability.

[0003] CN110042551A discloses a fabric that resists curling and allows for easy cutting. The fabric utilizes a first yarn that is alternately looped on every other needle to form a warp pile structure for the face weave. Each second yarn is simultaneously looped on two adjacent needles to form a heavy warp flat structure for the ground weave. The face and ground weaves are combined to form the fabric's body, allowing the fabric to resist curling and unraveling during cutting. However, this fabric has a long surface extension line, making it prone to looping, reversed pile, and snagging. Furthermore, the fabric is heavy and airtight, and its high spandex content makes it prohibitively expensive, hindering market circulation.

[0004] CN212404414U discloses a warp-knitted fabric with wide opening and high recovery. The fabric comprises a warp-knitted structure with at least two yarns in the same direction and with the same gauge. This structure utilizes an open-thread method to achieve wide opening, high recovery, a soft feel, and the ability to freely cut the warp direction. However, this patent application easily results in poor surface quality, such as roughness, unevenness, and blurred texture, when applied to yarns with high twist and long hairiness, failing to improve the fabric's appearance or wearability. Technical issues

[0005] The invention provides a warp-knitted staple fabric which has the characteristics of no curling, flatness and elasticity. Technical Solutions

[0006] A smooth, elastic, and curl-resistant warp-knitted staple fabric comprises a fabric body, the fabric body being woven from at least two types of yarns, including elastic yarn and inelastic staple yarn, the staple yarn having a denier of 50-180, the elastic yarn being woven into open coils within the fabric body, the open coils having no intersections at the base of the extension lines, and forming a smooth elastic layer on the fabric body, the staple yarn and the elastic yarn being fully or partially arranged in the same direction during weaving; and the surface roughness amplitude (SRA) of the front and back surfaces of the fabric body being ≤40 μm.

[0007] The spun yarn is any one or more combinations of cotton, regenerated cellulose fiber, acrylic fiber and PET; the elastic yarn is spandex, PTT or core-spun yarn; the fineness of the spun yarn is preferably between 60-135 denier.

[0008] The elastic yarn is woven using a fully open warp plain weave structure.

[0009] The staple yarn is knitted in an open warp satin weave with a lapping number of 1-0 / 1-2 / 2-3 / 2-1 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a lapping number of 0-1 / 2-1 / / .

[0010] The staple yarn is knitted in a closed warp satin weave with a lapping number of 0-1 / 2-1 / 3-2 / 1-2 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a lapping number of 0-1 / 2-1 / / .

[0011] The staple yarn is knitted in a fully open warp satin weave with a yarn lapping number of 0-1 / 1-2 / 3-2 / 2-1 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a yarn lapping number of 0-1 / 2-1 / / .

[0012] The staple yarn is knitted in a two-needle closed warp plain weave and in a 1-0 / 1-2 / / inlay yarn motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn motion mode.

[0013] The staple yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode.

[0014] The staple yarn is knitted in a three-needle closed warp plain weave and in a 1-0 / 2-3 / / inlay yarn number motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode.

[0015] The staple yarn is knitted in a three-needle open warp plain weave and in a 0-1 / 3-2 / / inlay yarn motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn motion mode. Beneficial effects

[0016] Elastic yarns are woven into open loops. The inelastic and elastic yarns are oriented in the same direction, either in whole or in part, during weaving. When the fabric is stretched in the warp direction, the elastic yarns return to the same direction as the inelastic yarns, quickly returning to their original state. This results in no curling or minimal curling. The open loops of the elastic yarn avoid intersecting at the base of the coil extension line, resulting in a smoother elastic layer. The fabric as a whole exhibits a smooth, elastic, and cottony feel without curling. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG1 is a schematic diagram of an embodiment 1 of an open coil in the present invention;

[0018] FIG2 is a schematic diagram of a second embodiment of an open coil according to the present invention;

[0019] FIG3 is a schematic diagram of a closed coil according to an embodiment of the present invention;

[0020] FIG4 is a schematic diagram of a second embodiment of a closed coil according to the present invention;

[0021] FIG5 is an organizational structure diagram of the first embodiment of the present invention;

[0022] FIG6 is an organizational structure diagram of the second embodiment of the present invention;

[0023] FIG7 is an organizational structure diagram of Example 3 of the present invention;

[0024] FIG8 is an organizational structure diagram of a fourth embodiment of the present invention;

[0025] FIG9 is an organizational structure diagram of a fifth embodiment of the present invention;

[0026] FIG10 is an organizational structure diagram of Example 6 of the present invention;

[0027] FIG11 is an organizational structure diagram of the seventh embodiment of the present invention. Best Mode for Carrying Out the Invention

[0028] 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.

[0029] 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.

[0030] 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.

[0031] Example 1

[0032] As shown in Figures 1-4, a smooth, elastic, and anti-curling warp-knitted staple fabric includes a fabric body, which is woven with at least two yarns including elastic yarn and inelastic staple yarn, the fineness of the staple yarn is between 50 and 180 denier, and the elastic yarn is woven in the fabric body with an open warp plain structure to form open coils, and the open coils have no intersection at the base of the extension line, forming a flat elastic layer on the fabric body, and the staple yarn and the elastic yarn are all or partially arranged in the same direction during weaving; tested with a Fabric Touch Tester, the SDL Atlas standard is obtained: the surface roughness amplitude SRA of the front and back sides is ≤40um.

[0033] The elastic yarn has a fully open weave structure, while the staple yarn can have a fully open weave structure, a partially open weave structure and a partially closed weave structure, or the staple yarn can have a fully closed weave structure.

[0034] Through the mutual cooperation of elastic yarn and inelastic staple yarn, the staple yarn and elastic yarn are all or partially arranged in the same direction during weaving. When the fabric is stretched in the warp direction, the elastic yarn returns to the same direction as the inelastic yarn and can quickly return to its original state. Therefore, the hem does not curl or the curling angle is very small after stretching, thereby achieving the effect of no curling or very small curling.

[0035] For smoothness, elastic yarns are primarily woven to form open loops, taking advantage of the lack of intersections at the base of the stretching line. Spun yarns, due to their twist, are rigid and feel hard. When the loops are formed, the unstable twist forces the loops to untwist, causing them to skew, resulting in an uneven surface. When the elastic yarn is placed before the needle and laterally moved back and forth, open loops form. Compared to closed loops, these open loops do not intersect at the base of the stretching line, resulting in no intersections and a smoother surface. During the interweaving of spun and elastic yarns, the elastic yarn's contraction further causes the spun yarn to arch, creating unevenness on the fabric surface and base. Open loops, unlike closed loops, do not experience the same significant inward force that forces the loops to contract, lessening the impact on the spun yarn's loops. Therefore, the smoother the elastic yarn structure, the less impact the elastic yarn's contraction has on the spun yarn, resulting in a smoother fabric surface.

[0036] The spun yarn can be any one or more combinations of cotton, regenerated cellulose fiber, acrylic fiber and PET; the elastic yarn can be spandex, PTT or core-spun yarn; the fineness of the spun yarn is preferably between 60-135 denier.

[0037] There are different combinations of specific weaving methods for staple yarns and elastic yarns.

[0038] Example 2

[0039] Mainly refer to Figures 5-11 and Figure 6, the staple yarn adopts an open warp satin weave and is woven in a motion mode with a padding number of 1-0 / 1-2 / 2-3 / 2-1 / / . At the same time, the elastic yarn adopts a two-needle open warp plain weave and is woven in a motion mode with a padding number of 0-1 / 2-1 / / .

[0040] Alternatively, referring mainly to FIG7 , the staple yarn is woven with a closed warp satin weave and a padding number of 0-1 / 2-1 / 3-2 / 1-2 / / , and the elastic yarn is woven with a two-needle open warp plain weave and a padding number of 0-1 / 2-1 / / .

[0041] Alternatively, referring mainly to FIG8 , the staple yarn is woven with a fully open warp satin weave and a 0-1 / 1-2 / 3-2 / 2-1 / / motion pattern, and the elastic yarn is woven with a two-needle open warp plain weave and a 0-1 / 2-1 / / motion pattern.

[0042] Alternatively, referring mainly to FIG5 , the staple yarn is knitted with two-needle closed warp plain weave and in a motion of inlay yarn number 1-0 / 1-2 / / , and the elastic yarn is knitted with two-needle open warp plain weave and in a motion of inlay yarn number 0-1 / 2-1 / / .

[0043] Alternatively, referring mainly to FIG9 , the staple yarn is knitted with a two-needle open warp plain weave and a lapping number of 0-1 / 2-1 / / , and the elastic yarn is knitted with a two-needle open warp plain weave and a lapping number of 0-1 / 2-1 / / .

[0044] Alternatively, referring mainly to FIG10 , the staple yarn is knitted with a three-needle closed warp plain weave and a padding number of 1-0 / 2-3 / / , and the elastic yarn is knitted with a two-needle open warp plain weave and a padding number of 0-1 / 2-1 / / .

[0045] Alternatively, referring mainly to FIG11 , the staple yarn is knitted with a three-needle open warp plain weave and a padding number of 0-1 / 3-2 / / , and the elastic yarn is knitted with a two-needle open warp plain weave and a padding number of 0-1 / 2-1 / / .

[0046] The following is an explanation using a production example.

[0047] 1. Warping of yarn used for warp knitting:

[0048] 1) Warping of staple fiber blended yarn

[0049] Warping machine model: Karl Mayer DS DS21 / 30DNC, negative yarn feeding.

[0050] Warping temperature: 23°C, Warping humidity: 65%

[0051] The workshop sets the process parameters under the above temperature and humidity conditions.

[0052] 2) Warping of spandex

[0053] Warping machine model: Karl Mayer DSE21 / 21EC, positive yarn feeding.

[0054] Warping temperature: 23°C, Warping humidity: 65%

[0055] The workshop sets the process parameters under the above temperature and humidity conditions.

[0056] 2. Weaving

[0057] Weaving machine model: Karl Mayer HKS4-1EL tricot machine

[0058] Machine gauge: E32

[0059] Number of combs: 3 bars

[0060] Yarn threading method: short fiber blended yarn, elastic yarn full threading

[0061] Raw materials: This fabric uses two different types of yarns. The short fiber blended yarn is preferably 87.3 denier; the elastic yarn is spandex yarn, preferably 30 denier.

[0062] Weaving process: To prevent the staple blended yarn from becoming skeined due to excessive twist, which would increase weaving difficulties, the staple blended yarn is separated into two combing bars and woven using a two-needle closed warp plain weave with a padding number of 1-0 / 1-2 / / . The elastic yarn is woven using a two-needle open warp plain weave in the same direction with a padding number of 0-1 / 2-1 / / .

[0063] 3. Post-processing

[0064] Washing--Pre-dyeing--Overflow dyeing--Dehydration--Setting and drying--Finishing

[0065] 4. Fabric style

[0066] Width: 195cm

[0067] Weight: 180gsm

[0068] Ingredients: 60% Acrylic 26% Modal 14% Elastane

[0069] 5. Fabric characteristics and advantages

[0070] 1) No curling in the warp direction and elasticity: After gently stretching the fabric along the warp direction by hand, there is basically no curling. Tensile test: M&S P15A 1.5kgf, warp opening 45%, weft opening 105%.

[0071] 2) Surface smoothness: Tested with the Fabric Touch Tester, the SDL Atlas standard is obtained: the surface roughness amplitude SRA for evaluating smoothness is ≤40μm. The SRA (surface roughness amplitude) measures the average difference between the peak and trough values ​​of the roughness wave. The larger the value, the bumpier the vertical direction and the less smooth the fabric.

[0072] Comparative Example: Staple yarn was knitted using a two-needle closed warp plain weave with a lapping pattern of 1-0 / 1-2 / / . Elastic yarn was knitted using a two-needle closed warp plain weave with a lapping pattern of 1-0 / 1-2 / / . Aside from the different structures, all other production elements, processes (weaving and dyeing and finishing), and steps were identical. A comparison table of specific FTT test data was generated. Specific FTT test data is shown in Table 1.

[0073] Table 1

[0074]

[0075] 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. A flat, elastic, and anti-curling warp-knitted staple fabric, comprising a fabric body, characterized in that: The fabric body is woven with at least two types of yarns, including elastic yarn and inelastic spun yarn. The fineness of the spun yarn is between 50 and 180 denier. The elastic yarn is woven into open coils in the fabric body. The open coils have no intersections at the base of the extension line, forming a flat elastic layer on the fabric body. The spun yarn and the elastic yarn are all or partially arranged in the same direction during weaving. The surface roughness amplitude SRA of the front and back surfaces of the fabric body is ≤40 μm.

2. The flat, elastic, and curl-proof warp-knitted staple fabric according to claim 1, characterized in that: The spun yarn is any one or more combinations of cotton, regenerated cellulose fiber, acrylic fiber and PET; the elastic yarn is spandex, PTT or core-spun yarn; the fineness of the spun yarn is preferably between 60-135 denier.

3. The flat, elastic, and curl-resistant warp-knitted staple fabric according to claim 1, characterized in that: The elastic yarn is woven using a fully open warp plain weave structure.

4. The flat, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in an open warp satin weave with a lapping number of 1-0 / 1-2 / 2-3 / 2-1 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a lapping number of 0-1 / 2-1 / / .

5. The flat, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a closed warp satin weave with a lapping number of 0-1 / 2-1 / 3-2 / 1-2 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a lapping number of 0-1 / 2-1 / / .

6. The smooth, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a fully open warp satin weave with a yarn lapping number of 0-1 / 1-2 / 3-2 / 2-1 / / , and the elastic yarn is knitted in a two-needle open warp plain weave with a yarn lapping number of 0-1 / 2-1 / / .

7. The smooth, elastic, and curl-resistant warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a two-needle closed warp plain weave and in a 1-0 / 1-2 / / inlay yarn motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn motion mode.

8. The smooth, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode.

9. The smooth, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a three-needle closed warp plain weave and in a 1-0 / 2-3 / / inlay yarn number motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn number motion mode.

10. The smooth, elastic, and anti-curling warp-knitted staple fabric according to any one of claims 1 to 3, characterized in that: The staple yarn is knitted in a three-needle open warp plain weave and in a 0-1 / 3-2 / / inlay yarn motion mode, and the elastic yarn is knitted in a two-needle open warp plain weave and in a 0-1 / 2-1 / / inlay yarn motion mode.

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