CONTINUOUS POLYESTER FIBER TEXTILE CLOTH, PROCESSING EQUIPMENT AND METHOD

Abstract

The specification discloses a continuous polyester fiber textile cloth that can be torn into pieces, processing equipment and a processing method. By ultrasonic hot-melting technology, the polyester fiber textile cloth is subjected to the high temperature generated by the high frequency generated by the action of a metal knife mold and an ultrasonic welding head, so that the thread of the loop layers and the base layer are melted in a line to form a thin line melting body that can be torn apart. The knife mold and the ultrasonic welding head are close to each other and resonate to generate heat. When they leave each other, the resonance disappears and the heat decreases, so as to realize the formation and temperature control of a linear high temperature zone.

Claims

1. A continuous fiber textile cloth that can be torn into pieces, comprising: a continuously extending fiber textile cloth comprising a base layer woven from yarn and a loop layer located on at least one side of the base layer; wherein the fiber textile cloth includes a plurality of melting bodies at intervals along a length direction of the fiber textile cloth, and each melting body is configured to span from approximately a first marginal edge portion of the fiber textile cloth to approximately a second marginal edge portion of the fiber textile cloth located on an opposite side of a width of the fiber textile cloth relative to the first marginal edge portion; wherein the melting bodies are defined by melted and pressed material of the base layer and the loop layer of the fiber textile cloth at the melting bodies, such that each melting body defines a thickness that is less than or equal to a thickness of the base layer of the fiber textile cloth outside the melting bodies and is substantially consistent from approximately the first marginal edge portion of the fiber textile cloth to approximately the second marginal edge portion of the fiber textile cloth, the melted and pressed material extends substantially uninterrupted from approximately the first marginal edge portion to approximately the second marginal edge portion, is thermally damaged and embrittled, and thereby defines a connection strength such that the melting bodies can be manually torn along a length thereof; whereby by tearing along one of the melting bodies, a single piece of textile cloth can be separated from the continuous fiber textile cloth; and after tearing, a part of the melting body remains on an outer edge portion of adjacent unmelted fiber textile cloth of the single piece of textile cloth and binds off said outer edge portion.

2. The continuous fiber textile cloth according to claim 1, wherein the melting body is configured to be in the form of a straight line, a curved line, a zigzag line, or a bent line.

3. The continuous fiber textile cloth according to claim 1, wherein the thickness of each melting body is 0.01-2 mm, and a width of each melting body is 1-5 mm.

4. The continuous fiber textile cloth according to claim 1, wherein a width of the single piece of textile cloth is consistent with the width of the fiber textile cloth and the length of the single piece of textile cloth is 5 cm-200 cm.

5. The continuous fiber textile cloth according to claim 1, wherein the first marginal edge portion and the second marginal edge portion comprise heat-melt cutting edges.

6. The continuous fiber textile cloth according to claim 1, wherein both sides of the base layer include a respective loop layer.

7. The continuous fiber textile cloth according to claim 1, further comprising an inner core, and the fiber textile cloth including the melting bodies is wound on the inner core.

8. The continuous fiber textile cloth according to claim 1, wherein the fiber textile cloth including the melting bodies is stacked in a container in a Z-shaped continuous folding manner.

9. The continuous fiber textile cloth according to claim 1, wherein the base layer is warp-knitted, the base layer comprises loop units composed of woven threads, and the loop units are mutually interwoven to form constraints.

10. The continuous fiber textile cloth according to claim 1, wherein the base layer is weft-knitted and comprises a semi-loop unit composed of woven threads, and the semi-loop units rimmed by adjacent woven threads are mutually interwoven.

11. The continuous fiber textile cloth according to claim 1, wherein each melting body defines constraints between loop knitting units of the loop layer and loop units of the base layer that are damaged, and defines loop knitting units that are shrunken relative to loop knitting units of unmelted loop knitting units of the fiber textile cloth.

12. The continuous fiber textile cloth according to claim 1, wherein the melting bodies are formed by heating, melting, pressing and extruding the base layer and the loop layer in a range of 150 C. and 400 C. between a knife mold extending along the width of the fiber textile cloth and an ultrasonic welding head operating at a vibration frequency in a range of 2000-50,000 times/second, to thin the material in the melting bodies.

13. The continuous fiber textile cloth according to claim 1, wherein the continuous fiber textile cloth includes one or more of (i) polyester fibers, (ii) polyester fibers and non-polyester fibers, or (iii) polyester fibers and nylon fibers.

14. A processing equipment for continuous fiber textile cloth that can be torn into pieces, comprising an ultrasonic welding head and a metal knife mold, wherein the metal knife mold comprises a knife edge extending along substantially an entire width of the textile cloth; wherein the knife edge is configured to contact an upper surface of the fiber textile cloth, and the ultrasonic welding head is configured to contact a lower surface of the fiber textile cloth; wherein the knife edge of the metal knife mold is pressable into contact with and down through the fiber textile cloth to contact the ultrasonic welding head and configured to resonate with the ultrasonic welding head, and the ultrasonic welding head is configured to resonate and to cause the knife edge to resonate therewith to thereby produce a temperature zone in contact with the textile cloth configured to heat, melt, press, extrude and thereby thin a base layer and any loop layers of the fiber textile cloth between the metal knife mold and the ultrasonic welding head, and form a melting body in the textile cloth having a connection strength within a range wherein the melting body can be broken by tearing by a user.

15. The processing equipment according to claim 14, wherein the ultrasonic welding head is configured to vibrate within a range of 2000-50000 times/second, and configured to generate a heating temperature within a range of 150-400 C.

16. The processing equipment according to claim 14, configured to press the knife edge down into contact with the fiber textile cloth for a duration of 0.02-1 second.

17. The processing equipment according to claim 14, wherein the knife edge defines a triangular or tapered shape.

18. A method for manufacturing a continuous fiber textile cloth that can be torn into pieces, the method comprising: passing a continuous fiber textile cloth comprising a base layer and loop layers through an ultrasonic heater; heating and melting a portion of the base layer and loop layers along substantially an entire width of the textile cloth with the ultrasonic heater; and pressing and extruding and thereby thinning said heated and melted material to form one or more melting bodies spanning said substantially entire width and having a connection strength within a range wherein the melting bodies can be broken by tearing by a user, and which can be used to separate a single piece of textile cloth from the continuous fiber textile cloth at one of the melting bodies.

19. The method according to claim 18, wherein the ultrasonic heater comprises an ultrasonic welding head and the method further comprises: contacting a knife edge of a metal knife mold along the substantially entire width of the textile cloth on an upper surface of the fiber textile cloth; contacting the ultrasonic welding head on a lower surface of the fiber textile cloth; pressing the knife edge of the metal knife mold down through the fiber textile cloth into contact with the ultrasonic welding head; vibrating the ultrasonic welding head; and resonating the knife edge with the ultrasonic welding head, thereby producing a temperature zone configured for said heating and melting of said portion of the base layer and loop layers.

20. The method according to claim 19, wherein the step of vibrating the ultrasonic welding head includes vibrating the ultrasonic welding head at a vibration frequency within a range of 2000-50000 times/second, and the step of producing a temperature zone includes generating a heating temperature within a range of 150-400 C.

21. The method according to claim 19, including performing the steps of contacting and pressing the fiber textile cloth with the knife edge for a duration of 0.02-1 second.

22. The method according to claim 19, further comprising: performing the extruding step for a predetermined period of time; after completing the extruding step, discontinuing the ultrasonic vibration; removing the knife edge from contact with the textile cloth; and forming a next melting body at a different location along a length of the continuous fiber textile cloth.

23. The method according to claim 22, including controlling operation of the metal knife mold and the ultrasonic vibration of the ultrasonic welding head by a control signal.

24. The method according to claim 19, wherein the pressing and extruding steps include forming a concave upper surface of the melting body with the knife edge.

25. The method according to claim 24, wherein the knife edge defines a triangular or tapered shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The present invention will be described in further detail below with reference to the accompanying drawings and preferred embodiments. However, those skilled in the art will appreciate that these drawings are drawn for purposes of explaining preferred embodiments only and should therefore not be taken as limiting the scope of the invention. Unless otherwise indicated, the drawings are merely schematic representations of the composition or construction of the described objects and may contain exaggerated representations and are not necessarily drawn to scale.

[0061] FIG. 1 is the schematic diagram of the continuous polyester fiber textile cloth that can be torn into pieces by winding;

[0062] FIG. 2 is a schematic diagram of the tearing process of the continuous polyester fiber textile cloth that can be torn into pieces;

[0063] FIG. 3 is a partial cross-sectional view of the continuous polyester fiber textile cloth that can be torn into pieces;

[0064] FIG. 4 is a diagram of the base layer woven by a warp knitting process of a continuous polyester fiber textile cloth that can be torn into pieces;

[0065] FIG. 5 is a diagram of the base layer woven by a weft knitting process of the continuous polyester fiber textile cloth that can be torn into pieces;

[0066] FIG. 6 is a schematic view of the processing of the continuous polyester fiber textile cloth that can be torn into pieces.

DETAILED DESCRIPTION

[0067] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Those skilled in the art will appreciate that these descriptions are descriptive, exemplary only, and should not be construed as limiting the scope of protection of the present invention.

[0068] It should be noted that like numerals refer to like items in the following figures, so once an item is defined in one figure, it may not be further defined and explained in subsequent figures.

[0069] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms front, rear, etc. is based on the orientation or positional relationship shown in the accompanying drawings, or is usually placed when the product of the invention is used. The orientation or positional relationship is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0070] As shown in FIGS. 1-3, a continuous polyester fiber textile cloth that can be torn into pieces comprises a continuously extending polyester fiber textile cloth A. The polyester fiber textile cloth A consists of a base layer 1 woven from yarns and loop layer 2 arranged on at least one side of the base layer 1.

[0071] As shown in FIG. 4, the base layer 1 is prepared by a warp knitting process; as shown in FIG. 5, the base layer 1 is prepared by a weft knitting process. The base layer 1 prepared by the above two processes has a loop unit a or a semi-loop unit b composed of woven threads.

[0072] The loop units a on the warp lines of the base layer prepared by the warp knitting process are interlocked, and a lead wire of the loop units a on the weft lines passes through the loop units a on the adjacent weft lines. Another lead wire is used to surround the annular unit a forming a diagonal position, so that the adjacent annular units a are intertwined to form a constraint.

[0073] The woven threads of the base layer prepared by the weft knitting process are bent in a wave shape to form adjacent semi-loop units b spaced in forward and reverse directions on the weft. The semi-loop units b formed by adjacent weft threads are intertwined with each other.

[0074] The interwoven loop units a or semi-loop units b provide the entire base layer 1 with tear resistance, thereby making the polyester fiber textile cloth more durable.

[0075] The loop knitting units of the loop layer 2 protrude from the surface of the base layer 1 and are arranged on the surface of the base layer 1 in a matrix manner. Each loop knitting unit is further interwoven with the loop unit a or semi-loop unit b of the base layer 1, so that the base layer 1 and the loop layer 2 are combined, which improves the water absorption and cleaning ability of the polyester fiber textile cloth and also improves the strength of the textile cloth.

[0076] As shown in FIGS. 1-3, the continuous polyester fiber textile cloth is provided with a plurality of thin line melting bodies 3 at intervals along the length direction.

[0077] The thin line melting bodies 3 can span the width of the polyester fiber textile cloth, or can be interlaced to form a grid, so as to separate the long polyester fiber textile cloth to form several textile cloth units M.

[0078] These thin line melting bodies 3 are formed by heating, melting and pressing the base layer 1 and the loop layers 2, and the thickness of the thin line melting bodies 3 are less than or equal to the thickness of the base layer 1. The thin line melting bodies 3 are concave on the surface of the polyester fiber textile cloth, and its position can be known visually.

[0079] It should be understood that, through hot-melt pressing, firstly, the toughness of the fibers itself at the thin line melting bodies 3 are thermally damaged and becomes brittle; secondly, the constraints between the loop units a of the base layer 1 and the constraints between the loop knitting unit and the loop units a of the base layer 1 at this place are both damaged; thirdly, the thin line melting bodies 3 at this place are concave to make the stress more concentrated to form a tearing notch. That is, the thin line melting bodies 3 are easily broken by force.

[0080] Accordingly, the user can tear along the thin line melting body 3 to separate out a single piece of textile cloth. Depending on the amount of objects to be cleaned, the size and length of the cloth can be determined by tearing it off without cutting it with a knife or a sharp blade.

[0081] Preferably, the thin line melting body 3 can be in the form of a straight line, a curved line, a zigzag line or a bent line. In this embodiment, the thin line melting bodies 3 run through the width of the polyester fiber textile cloth and are distributed on the long polyester fiber textile cloth at certain intervals, thereby separating the polyester fiber textile cloth into textile cloth units M with the same size, which is of convenience of users.

[0082] Preferably, the material of the base layer 1 is all polyester, and the material of the loop layer 2 is mixed polyester formed of polyester and nylon. Among them, the base layer 1 accounts for 30-32%, and the loop layer 2 accounts for 68-70%.

[0083] As shown, the matrix arrangement of the loop knitting units of the terry layer 2 will form longitudinal terry spacing lines, and the thin strand melt 3 is parallel to the longitudinal terry spacing lines. The loop knitting units on both sides of the thin line melting bodies 3 melt and shrink and form lodging, so that the loop layers 2 on both sides of the thin line melting bodies 3 gradually changes from thin to thick from the thin line melting body 3.

[0084] As shown in FIGS. 1-3, the textile cloth unit M spaced apart by the longitudinal thin line melts 3 is separated from the integral continuous polyester fiber textile cloth to form a single piece of textile cloth. The width of the single piece of textile cloth is the same as the width of the long polyester fiber textile cloth, and the length of the single piece of textile cloth is 5 cm-200 cm.

[0085] Preferably, the two sides of the base layer 1 are respectively provided with loop layers 2, and the base layer 1 and the two loop layers 2 are heated and melted and then pressed to form a thin line melting body 3. The thin line melting body 3 is located at the midline of the thickness of the polyester fiber textile cloth to form concave wire grooves on both surfaces of the polyester fiber textile cloth.

[0086] As shown in the figure, the thin line melting body 3 has a thickness of 0.01-2 mm and a width of 1-5 mm. With a thickness of 0.01-2 mm, the thin line melting body 3 has the ability to connect the textile cloth units M on both sides without external force tearing, so that the polyester fiber woven fabric maintains continuity. This in turn ensures that the connection strength is within a range that can be broken after being torn by the user, which is convenient for the user to tear and separate the textile cloth into a single piece. At the same time, the width of the thin line melting body 3 also affects its connection strength. In addition, the width range of 1-5 mm makes the thin line melting body 3 visible without wasting cloth.

[0087] In addition, both sides of the continuous polyester fiber textile cloth are bound off by heat-melting cutting edges, which can prevent the textile cloth from running silk, After any thin line melting bodies 3 on the continuous polyester fiber textile cloth is torn and separated from the textile cloth unit M, a part of the thin line melting body 3 remains on the outer edge of the remaining continuous polyester fiber textile cloth, which still plays the role of binding off.

[0088] In order to facilitate the storage and taking of the continuous polyester fiber textile cloth, this embodiment provides a placement form of the continuous polyester fiber textile cloth, that is, a roll-type polyester fiber textile cloth. Of course, other placement forms such as a folding and pulling type are also possible.

[0089] As shown in FIG. 1, the roll-type polyester fiber textile cloth comprises an inner core 4 and the polyester fiber textile cloth A with the thin line melting bodies 3 wound outside the inner core 4, and the inner core 4 is cylindrical paper tube.

[0090] It should be noted that the thin line melting body 3 remaining on the outer edge after tearing is hard, thin and has rough edges. However, the outer surface of the polyester fiber textile cloth is rough due to the loop layer 2, and the thin line melting body 3 remaining on the outer edge can maintain a large friction force with the outer surface of the polyester fiber textile cloth. Even the thin line melting body 3 remaining on the outer edge can be tied in the loop layer 2 on the outer surface of the polyester fiber textile cloth. Therefore, the thin line melting body 3 remaining on the outer edge can be attached to the outer surface of the polyester fiber textile cloth, so that the roll-type polyester fiber textile cloth can maintain a stable winding shape, and is not easy to fall off and be scattered.

[0091] This embodiment also provides processing equipment for preparing the above polyester fiber textile cloth. The processing equipment is ultrasonic equipment, which mainly involves preparing thin line melting bodies 3 at intervals on the long polyester fiber textile cloth.

[0092] As shown in FIG. 6, the processing equipment comprises an ultrasonic welding head 10 and a metal knife mold 20 driven by a driving mechanism. The ultrasonic welding head 10 comprises an ultrasonic emitting device and a welding head. The ultrasonic emitting device converts the 220 V alternating current into a high-frequency ultrasonic signal, and then connects to the transducer and converts it into high-frequency vibration to drive the head to generate high-frequency ultrasonic vibration. The welding head has a rest surface on which the polyester fiber textile cloth is carried, and the polyester fiber textile cloth is conveyed on this rest surface.

[0093] The metal knife mold 20 comprises a knife edge s extending along the width direction of the textile cloth. Under the action of the driving mechanism, the knife edges of the metal knife mold 20 moves down to contact the surface of the polyester fiber textile cloth. As a result, the metal knife mold 20 resonates with the ultrasonic head 10 below the polyester fiber textile cloth, and the ultrasonic welding head 10 generates a linear high temperature zone. The width of the linear high temperature zone is the same as the width of the knife edge s. This linear high temperature zone melts the base layer 1 and the loop layers 2 of the polyester fiber textile cloth there. At the same time, the knife edge s and the head squeeze this part of the melt to form a thin line melting body 3. That is, the base layer 1 and the loop layers 2 are heated and melted by high-frequency ultrasonic waves to form a thin line melting bodies 3.

[0094] In the same way, the hot-melt cutting edges on both sides of the polyester fiber textile cloth can also be prepared in this way.

[0095] Preferably, the drive mechanism may be an air cylinder controlled by a pneumatic transmission system. In actual operation, as soon as the power supply starts to trigger the control signal, the control signal makes the pneumatic transmission system run and the cylinder pressurizes to drive the metal knife mold down, and at the same time the control signal makes the ultrasonic emitting device of the ultrasonic welding head 10 emit ultrasonic waves to make the welding head ultrasonically vibrate. The metal knife mold is pressed down and squeezed together with the ultrasonic welding head to squeeze the polyester fiber textile cloth, and the ultrasonic emission is removed after a certain period of time. The pressure of the pneumatic transmission system is decompressed, and the metal knife mold is lifted, thereby preparing a thin line melting body 3. After a certain period of time, the above procedure is continued to complete the preparation of the next thin line melting body 3.

[0096] Preferably, the vibration frequency of the ultrasonic welding head 10 is 2000-50000 times/second, the heating temperature of the ultrasonic welding head 10 is 150-400 C., and the duration for the knife edge to press down and contact the polyester fiber textile cloth is 0.02-1 second. It should be noted that the time and pressure of the knife edge s pressing down on the surface of the polyester fiber textile cloth need to be set reasonably, so as to avoid the situation where the polyester fiber textile cloth is fused or the thin line melting bodies 3 are too thick, which make it difficult to tear.

[0097] With this processing equipment and processing method, there is no need to preheat the metal knife mold and the ultrasonic welding head during preparation. The heat can be generated by pressing the contact to generate resonance, and the heat can be reduced when the resonance disappears, so as to realize the formation and temperature control of the linear high temperature zone. Therefore, continuous operation can be realized, and the temperature of the cutter head is basically consistent each time, so as to ensure the consistency of each thin line melting body 3.

[0098] The polyester fiber textile cloth that can be torn into pieces provided by the present invention has been introduced in detail above. The principles and implementations of the present invention are described herein by using specific examples, and the descriptions of the above embodiments are only used to help understand the present invention and the core idea. It should be pointed out that for those skilled in the art, without departing from the principle of the present invention, several improvements and modifications can also be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.