Abstract:
A polyester microfiber velveteen coral weft blanket, adopting polyester filament or polyester and nylon multi-filament of 0.58 dtex or smaller specification as row stock, 110˜167 dtex polyester FDY (fully drawn yarn) or DTY (draw texturized yarn) as ground thread, said polyester filament or polyester and nylon multi-filament takes up 40˜80% of the component, said 110˜167 dtex polyester FDY (fully drawn yarn) or DTY (draw texturized yarn) takes up 60˜20%, said percentages are mass percents; the production processes are: raw stock preparation, weave on the circular slitting weft knitting machine, heat setting, dyeing or printing, finishing, napping, wrong side shearing, heat setting, finished blanket, inspection and packing, the pile has unique style reaching that of the submarine coral, providing the product with thermal property, lightness, soft handle that can sufficiently meet the requirements of the market, and the techniques are reasonable, effective and suitable for the production of blankets.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION  
       [0001]     This patent application claims the priority benefit of a Chinese patent application No. 200510061835.9 filed on Dec. 6, 2005.  
       FIELD OF THE INVENTION  
       [0002]     This patent is involved in a blanket made from the raw stock of polyester microfiber produced by being woven on a circular slitting weft knitting machine before being processed with a special finishing as well as related production methods.  
       BACKGROUND OF THE INVENTION  
       [0003]     At present, blanket products popular in the market are pure wool blanket, blankets made by mixture spinning of wool and other raw stocks (e.g., acrylic and viscose), acrylic blanket, cotton blanket, double-face napping poly fleece blanket made from polyester on circular weft knitting machine and the polyester microfiber velveteen coral blanket invented by our company that is made from polyester microfiber on double needle bar raschel warp machine. Pure wool blanket has good thermal property but it cannot prevent mildew and moths and will be itchy when touching skin contact; the same to mixture spinning blanket; though acrylic blanket is colorful, mildew proofing and moths proofing, it has insufficient handle and skin contact property; cotton blanket has fine hygroscopic property, soft and comfortable handle, but its still far from the requirements of the market. Since the pile of poly fleece blanket is napped by napper, the pile surface of this kind of blanket is inferior to blankets made by pile machine. The polyester microfiber velveteen coral blanket invented by our company that is made from polyester microfiber on double needle bar raschel warp machine is a functional blanket with the thermal property over twice as good as that of thermal underwear (the thermal preservation rate of thermal underwear is 20%, while that of polyester microfiber velveteen coral blanket can reach 70%) and the gas permeability over 5 times as that of thermal underwear (the gas permeability of is 120 mm/s, while that of polyester microfiber velveteen coral can reach 700 mm/s), in term of drape, its performance is equal to that of silk blanket (both blankets have the drape coincidence of 40% or so), it can sufficiently meet the requirements of the market. Recently, through market research and survey, we have found that the market needs a real coral-style blanket whose thermal property, permeability and drape maintains the inherent features of warp knitting polyester microfiber velveteen coral blanket. Though the pile style of the warp knitting polyester microfiber velveteen coral blanket is similar to coral, it is still not as beautiful as submarine coral; though it is easy for people to associate warp knitting with weft knitting, double-face napping poly fleece blanket made from polyester on general circular weft knitting machine are not real blankets, circular slitting machine must be adopted to solve the problems of normal weft jersey stitch: high elasticity and dry linting or dropping of pile so as to produce real blankets with coral style, with the incomparable visual effect and the handle softer and more comfortable than warp knitting polyester microfiber velveteen coral blankets, this kind of blankets have vast prospect.  
       SUMMARY OF THE INVENTION  
       [0004]     The principal technical problem of the invention is to provide a kind of polyester microfiber weft knitting velveteen coral blanket with unique style of pile, achieving the appearance style of submarine coral, which also has the thermal property, lightness, soft handle, fine permeability that can sufficiently meet the requirements of the market.  
         [0005]     Another purpose of this invention is to provide a production method for a kind of polyester microfiber weft knitting velveteen coral blanket, in which the blanket produced has unique style of pile, achieving the appearance style of submarine coral, which also has the thermal property, lightness, soft handle, fine permeability that can sufficiently meet the requirements of the market, and the techniques are reasonable and effective.  
         [0006]     The technical solution of this invention for solving the above initial technical problem is as follows: a kind of polyester microfiber velveteen weft knitting blanket, featured by adopting polyester-filament or polyester and nylon multi-filament of 0.58 dtex or smaller specifications as raw stock for pile, 110˜167 dtex polyester FDY (fully drawn yarn) or DTY (draw texturized yarn) as the ground thread, said polyester-filament or polyester and nylon multi-filament of 0.58 dtex or smaller specifications takes up 40˜80% of the component, and said 110˜167 dtex polyester FDY (fully drawn yarn) takes up 60˜20%, said percentages are mass percents.  
         [0007]     The technical solution of this invention for solving the above initial technical problem is as follows: a kind of said production method for the said polyester microfiber velveteen weft knitting blanket, featured by the following steps:  
         [0008]     (1) Raw stock preparation, choose and prepare raw stocks according to the said proportion;  
         [0009]     (2) Weave on the circular slitting weft knitting machine, gram weight of gray is 200˜600 g/m 2 , breadth should be in accordance with the customer&#39;s requirement;  
         [0010]     (3) Heat setting, temperature: 175˜185° C., fabric heating time: 45˜55 seconds;  
         [0011]     (4) Dyeing or printing, dyeing ingredients: disperse dyestuffs yellow 0.5˜1.5%, disperse dyestuffs blue 0.5˜1.5%, disperse dyestuffs red 1.5˜2.5%, acetic acid 0.3˜0.8%, levelling agent 0.3˜0.8%, said percentages are based on fabric weight, under the temperature of 60˜70° C., add the said dyestuff auxiliary, feed the fabric, after 45˜55 minutes, raise the temperature to 125˜135° C., keep the temperature for 25˜35 minutes, then close the steam valve, fill cold water in the interlayer of the dyeing machine, reduce the temperature to 75˜85° C. for sending out the cloth; printing ingredients are:  
         [0000]     disperse dyestuffs red 4˜6 g/l, disperse dyestuffs yellow 1˜3 g/l, disperse dyestuffs blue 0.5˜1.5 g/l, acetic acid 4˜6 g/l, urea 45˜55 g/l, plus sodium alginate paste, mix them into the printing paste for printing;  
         [0012]     (5) Finishing, dyeing finishing: NaOH 0.5˜1.5 g/l, hydrosulphite 0.5˜1.5 g/l, under the temperature of 65˜75° C. after 10˜20 minutes, add 20˜40 g/l of softening agent and 10-30 g/l of antistatic agent in the padding mangle of the setting machine, finishing after printing: steam the fabric under 170˜180° C. after drying; then washing: 0.5˜1.5 g/l of NaOH, 0.5˜1.5 g/l of hydrosulphite, under 65˜75° C., for 10˜20 minutes; then add 20˜40 g/l of softening agent and 10-30 g/l of antistatic agent in the padding mangle of setting machine for setting, double-layer blankets should be made into finished blankest after direct setting under 175˜185° C., single-layer wrong side napping blankets should be napped after drying under 155˜165° C.;  
         [0013]     (6) Napping, with napping machine, 26/30# curved needle stripping fillet, roller with rotating speed of 70˜90 r/min, cloth feeding speed of 7˜15 m/min, continuous napping on the wrong side of the fabric for 3˜5 times;  
         [0014]     (7) Wrong side shearing, cloth feeding speed of 6˜9 m/min, roller clutching speed of 700˜800 r/min, shearing speed of 700˜800 r/min;  
         [0015]     (8) Heat setting, under temperature of 175˜185° C., fiber heating time of 30˜40 seconds;  
         [0016]     (9) Finished blanket, inspection and packing.  
         [0017]     Before said dyeing or printing, the sea island polyester and nylon multi-filament need to receive alkali weight reduction processing in NaOH solution of 7˜9 g/l under the temperature of 75˜85° C. for 25˜35 minutes.  
         [0018]     Compared with existing technologies, this invention has the advantages as follows: 1. it&#39;s the newest type of blanket in the market adopting the newly developed polyester microfiber, the product has the handle softer than the skin of a baby and the skin contact property, and its drape has reached the level of the silk blanket (both have the drape coefficient of 40% or so). 2. As there are more air between the new microfibers, which can keep the warm air isolated from cold air outside, and the high specific surface area efficiently reflects the heat of human body and prevent the heat from losing, the blanket has the thermal property over twice as that of the thermal underwear (the thermal preservation rate of the latter is 20%, while that of the polyester microfiber weft velveteen coral blanket can reach 75%), and with the inherent firm structural texture of weft loop, the permeability of the blanket can be over five times as that of the thermal underwear (the permeability of the latter is 120 mm/s, while that of the polyester microfiber velveteen coral weft blanket can reach 900 mm/s). 3. Adopting the circular slitting weft knitting machine and the derivation weave that can solve the problem of droppings, it can overcome the defects of normal weft jersey stitch like excessive flexibility and pile droppings etc., e.g., it adopts the bottom cloth weave of 2-stitch wreathe and 2-stitch miss-lapping stitch, which can not only solve the flexibility problems of fabric, but also can tightly fix the pile on the bottom cloth without droppings, it also adopts appropriate napping clothing to solve the problems of cloth crimple when napping and the knap surface style after finishing so as to create the genuine coral-style blanket. 4. The extraordinarily comfortable visual effect is a breakthrough from traditional blankets, its pile of submarine coral style creates the particularly comfortable visual effect, after the novel technical processing, it will be colorful luster and the quality will not be influenced after repeated washing; the product is green and contains no substances hazardous to human body, it is also mildew proofing and moths proofing and will not result in skin allergy. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a drawing of bottom cloth weave of warp knitting;  
         [0020]      FIG. 2  is a drawing of pile loop of warp knitting;  
         [0021]      FIG. 3  is a drawing of bottom cloth weave of weft knitting;  
         [0022]      FIG. 4  is a drawing of pile loop of weft knitting;  
         [0023]      FIG. 5  is a sketch map of the curved needle of the tripping fillet napping machine. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     More detailed description of this invention is given as follows in combination with practices.  
       EXAMPLE 1  
       [0025]     Double dyeing velveteen coral blanket, breadth of the finished product is 130 cm, gram weight for double layer is 400 g/m 2 , and the production procedure is as follows:  
         [0026]     (1) Raw stock preparation, select and prepare raw stocks, adopting the 167 dtex/288 F (0.58 dtex) polyester DTY produced by Yizheng Chemical Fiber Company as raw stock for pile, and the 111 dtex/37 F polyester FDY produced by Yizheng Chemical Fiber Company as the ground thread, said 0.58 dtex polyester DTY takes up 65% of the component, and the 111 dtex/37 F polyester FDY takes up 35%, said percentages are mass percents;  
         [0027]     (2) Weave on the circular slitting weft knitting machine, gram weight of the gray is 230 g/m 2 , the breadth is 130 cm or in accordance with the customer&#39;s requirements; the circular slitting weft knitting machine adopts JL99 circular slitting machine produced by Wuxi Golden Dragon Manmade Furry Machinery Co., Ltd.  
         [0028]     (3) Heat setting, heat the fiber under 180° C. for 50 seconds;  
         [0029]     (4) Dyeing, ingredients for dyestuffs are: disperse dyestuffs yellow 1%, disperse dyestuffs blue 1%, disperse dyestuffs red 2%, glacial acetic acid 0.5%, levelling agent 0.5%, the levelling agent adopts type 802 levelling agent that can be purchased in Chinese market, for heavy fabric, add the said dyestuff auxiliary between 60˜70° C., feed the fabric, rise the temperature to 130° C. after 50 minutes and then keep the temperature for 30 minutes, then close the steam valve, fill cold water in the dyeing machine interlayer, reduce the temperature to 80° C. for sending out the cloth;  
         [0030]     (5) Dyeing finishing, 1 g/l of NaOH, 1 g/l of hydrosulphite, under 70° C., after 15 minutes, add 30 g/l of softening agent and 30 g/l of antistatic agent in the padding mangle of the setting machine for setting, said antistatic agent should be DAS antistatic agent that can normally be purchased in Chinese market, then carry out heat setting under 180° C., the heating time for the fiber should be 30˜40 seconds, and the breadth should be 130 cm;  
         [0031]     (6) Finished blanket, inspection and packing.  
         [0032]     Please see  FIGS. 1-4 , seeing from the bottom cloth weave loop chart of the warp knitting and the weft knitting, as the bottom cloth weave of warp knitting has less extensibility in both warp direction and weft direction, the flexibility of the fabric is weak, and the handle is relatively harder than that of weft knitting, while the bottom cloth weave of weft knitting has unique flexible loop structure, giving the fabric a softer and more comfortable handle, seeing form the pile loop structure of warp knitting, as there&#39;s only single loop in the bottom cloth, after the napping of the fabric, single fibers are easily pulled out from the fabric, while because there is double loop in the bottom cloth, single fibers are tightly clamped by the bottom cloth weave loop and are hardly pulled out from the fabric after napping, therefore, the bottom cloth weave loop of blanket by weft knitting is more tight, less easily dropping piles, more flexible and with better handle than that of blanket by warp knitting.  
         [0000]     Practice 2  
         [0033]     Velveteen coral single printing napping blanket, the breadth of the finished product is 130 cm, and the gram weight is 280 g/m 2 , its production procedure is as follows:  
         [0034]     (1) Raw stock preparation, select and prepare raw stocks, the 167 dtex/288 F (0.58 dtex) polyester DTY produced by Yizheng Chemical Fiber Company is adopted as stock of pile, the 167 dtex/37 F polyester FDY (fully drawn yarn) produced by Yizheng Chemical Fiber Company is adopted as the ground thread, said sea island polyester takes up 70% of the component, said 167 dtex/37 F polyester FDY (fully drawn yarn) takes up 30%, said percentages are mass percents;  
         [0035]     (2) Weave on the circular slitting weft knitting machine, the gram weight of the gray is 280 g/m 2 , and the breadth is 130 cm or in accordance with the customer&#39;s requirements;  
         [0036]     (3) Heat setting, under the temperature of 180° C., heats the fiber for 50 seconds;  
         [0037]     (4) Printing, ingredients for dyestuffs are: disperse dyestuffs red 5 g/l, disperse dyestuffs yellow 2 g/l, disperse dyestuffs blue 1 g/l, acetic acid 5 g/l, urea 50 g/l, plus sodium alginate paste, mix them into the printing paste for printing;  
         [0038]     (5) Printing finishing, steam the fabric under 170˜180° C. for aging after drying; then the wash cycle: NaOH 1 g/l, hydrosulphite 1 g/l, under the temperature of 70° C. for 15 minutes. And then add 30 g/l of softening agent and 30 g/l of antistatic agent in the padding mangle of the setting machine, then prepare for napping after drying under 160° C.;  
         [0039]     (6) Napping, adopting 26/30# curved needle stripping fillet napping machine, the rotating speed of the roller is 80 r/min, the cloth speed is 7˜15 m/min, wrong side napping for the fabric for 4 times continuously;  
         [0040]     The wire diameter for said 26/30# curved needle stripping fillet napping machine is 0.48×0.355 MM, the SECTION of the wire: is circle, HEIGHT A: 9.1 MM, the WORKING ANGLE X: 42°, the SETTING ANGLE Y: 78°, POINTS/(25.4 MM 2 ): POINTS PER SQUARE INCH: 280. Please consult  FIG. 5 .  
         [0041]     (7) Wrong side shearing, the cloth feeding speed is 6˜9 m/min, the roller-clutching speed is 700˜800 r/min, the shearing speed is 700˜800 r/min;  
         [0042]     (8) Heat setting, under temperature of 180° C., heat the fiber for 30˜40 seconds, the breadth is 133 cm;  
         [0043]     (9) Finished blanket, inspection and packing.  
         [0000]     Practice 3  
         [0044]     Double dyeing velveteen coral blanket, the breadth of the finished product is 165 cm, the gram weight for double-layer blanket is 400 g/m 2 , and the production procedure is as follows:  
         [0045]     (1) Raw stock preparation, select and prepare raw stocks, the sea island polyester produced by Yizheng Chemical Fiber Company is adopted as stock of pile, by now, said sea island polyester is a very thin polyester filament, normally under 0.1 dtex, or even 0.06 dtex. The 111 dtex/37 F polyester FDY (fully drawn yarn) produced by Yizheng Chemical Fiber Company is adopted as the ground thread, said sea island polyester takes up 60% of the component, said 111 dtex/37 F polyester FDY (fully drawn yarn) takes up 40%, said percentages are mass percents;  
         [0046]     (2) Weave on the circular slitting weft knitting machine, the gram weight of the gray is 220 g/m 2 , and the breadth is 165 cm or in accordance with the customer&#39;s requirements;  
         [0047]     (3) Heat setting, under the temperature of 180° C., heats the fiber for 50 seconds;  
         [0048]     (4) Alkali weight reduction, processing with NaOH solution of 8 g/l, under the temperature of 80° C., for 30 minutes;  
         [0049]     (5) Dyeing, ingredients of dyestuffs: disperse dyestuffs yellow 1%, disperse dyestuffs blue 1%, disperse dyestuffs red 2%, acetic acid 0.5%, leveling agent 0.5%, for heavy fabric, add the said dyestuff auxiliary between 60˜70° C., feed the fabric, rise the temperature to 130° C. after 45˜55 minutes and then keep the temperature for 30 minutes, then close the steam valve, fill cold water in the dyeing machine interlayer, reduce the temperature to 80° C. for sending out the cloth;  
         [0050]     (6) Dyeing finishing, NaOH 1 g/l, hydrosulphite 1 g/l, under the temperature of 70° C., after 15 minutes, add 30 g/l of softening agent and 30 g/l of antistatic agent in the padding mangle of the setting machine, the carry out heat setting under 180° C., the heating time of the fiber is 30˜40, and the breadth is 165 cm;  
         [0051]     (5) Finished blanket, inspection and packing.  
         [0000]     Practice 4  
         [0052]     Coral single printing-napping blanket, the breadth of the finished product is 133 cm, the gram weight is 280 g/m 2 , and the production procedure is as follows:  
         [0053]     (1) Raw stock preparation, select and prepare raw stocks, the polyester and nylon multi-filament produced by Yizheng Chemical Fiber Company is adopted as stock of pile, said polyester is a very thin polyester filament, normally under 0.6 dtex, or even 0.1 dtex. The 167 dtex/37 F polyester FDY (fully drawn yarn) produced by Yizheng Chemical Fiber Company is adopted as the ground thread, said polyester and nylon multi-filament takes up 80% of the component, said 167 dtex/37 F polyester FDY (fully drawn yarn) takes up 20%, said percentages are mass percents;  
         [0054]     (2) Weave on the circular slitting weft knitting machine, the gram weight of the gray is 280 g/m 2 , and the breadth is 133 cm or in accordance with the customer&#39;s requirements;  
         [0055]     (3) Heat setting, under the temperature of 180° C. heats the fiber for 50 seconds;  
         [0056]     (4) Alkali weight reduction processing with NaOH solution of 8 g/l, under the temperature of 80° C., for 30 minutes;  
         [0057]     (5) Printing, printing ingredients: disperse dyestuffs red 5 g/l, disperse dyestuffs yellow 2 g/l, disperse dyestuffs blue 1 g/l, acetic acid 5 g/l, urea 50 g/l, plus sodium alginate paste, mix them into the printing paste for printing;  
         [0058]     (6) Printing finishing: steam the fabric under 170˜180° C. after drying; then washing: 1 g/l of NaOH, 1 g/l of hydrosulphite, under 70° C., for 15 minutes; then add 30 g/l of softening agent and 30 g/l of antistatic agent in the padding mangle of setting machine for napping after drying under 160° C.;  
         [0059]     (7) Napping, adopting 26/30# curved needle stripping fillet napping machine, the rotating speed of the roller is 80 r/min, the cloth feeding speed is 7˜15 m/min, wrong side napping of the fabric for 4 times continuously;  
         [0060]     (8) Wrong side shearing, cloth feeding speed is 6˜9 m/min, roller clutching speed is 700˜800 r/min, the shearing speed is 700˜800 r/min;  
         [0061]     (9) Heat setting, under the temperature of 180° C. heat the fiber for 30˜40 seconds, the breadth is 133 cm;  
         [0062]     (10) Finished blanket, inspection and packing.