PLUSH MATTRESS PROTECTOR

Description

TECHNICAL FIELD

The present disclosure belongs to the technical field of beddings, and specifically, to a plush mattress protector.

BACKGROUND

A plush mattress protector refers to a functional home protective product that uses polyester fiber plush fabric as a core surface material, is matched with a dense base fabric and an elastic auxiliary structure, and employs a wrap-around or fitted sheet design for completely covering the surface and edges of a mattress.

With the gradual increase in requirements of people for aesthetic appearance, the surfaces of plush mattress protectors have gradually developed toward patterned decorations. At present, the patterns of the plush mattress protectors are generally formed by adopting jacquard, plush carving, and embossing processes. The jacquard process refers to a technique that creates natural concave-convex textures of high/low or dense/sparse piles in patterned areas by designing differentiated movement trajectories of guide bars during a weaving stage, thereby forming the patterns. The plush carving process refers to a technique that performs selective trimming only on the patterned areas by means of laser positioning or mechanical template fixation on the basis of original integral cut plush, thereby forming a layered texture with varying heights and forming the patterns. The embossing process refers to a technique that first embosses a pattern on a plush surface by means of high temperature and high pressure, then performs rapid cooling and shaping to form the pattern. However, the foregoing processes have the following problems.

1. Due to limitations of jacquard and plush carving equipment, it is impossible to produce a plush mattress protector with a fine pattern. In addition, long production time may lead to low production efficiency.

2. Because the embossing equipment performs embossing under high temperature and high pressure, and different plush mattress protectors have different adaptabilities to the temperature and pressure, the quality stability of the product cannot be guaranteed.

In view of this, a plush mattress protector is designed to solve the foregoing problems.

SUMMARY

To solve the problem proposed in the foregoing background, The present disclosure provides a plush mattress protector. The pattern is finer, and the pattern repeat can be enlarged to about 60 mm. In addition, the plush mattress protector features stable product quality, advanced technology, high production efficiency, low cost, and hand feel quality superior to that of products made by conventional processes, and thus is suitable for high-end clothing, home textiles, decorative articles, and beddings.

To achieve the objective described above, the present disclosure provides the following technical solutions. A plush mattress protector includes:

• • a plush fabric layer, which is knitted by a double-needle-bar warp knitting machine and then split by a plush splitting machine;
  • a pattern, which is formed on the plush fabric layer by applying a strongly alkaline material on a metal roller with an adaptive pattern of a roller machine, followed by roll pressing and etching with the metal roller of the roller machine; and a waterproof layer, which is formed on the plush fabric layer and the pattern by performing padding and roll-pressing via a padding machine, followed by dewatering via a centrifugal hydroextractor, and high-temperature setting via a setting machine.

Further, pretreatment prior to fabrication of the plush fabric layer includes specific steps as follows:

• • arranging ground yarns closely and evenly on an empty beam by a warping machine to form a ground yarn beam; and
  • arranging face yarns closely and evenly on an empty beam by the warping machine to form a face yarn beam.

Further, specific steps during fabrication of the plush fabric layer are as follows:

• • mounting the ground yarn beam on let-off frames corresponding to four guide bars that control knitting of a front base fabric and a rear base fabric on the double-needle-bar warp knitting machine, and enabling the ground yarn to be successively threaded through guide needles of the four guide bars that control the knitting of the front base fabric and the rear base fabric on the double-needle-bar warp knitting machine by means of a non-spaced threading method;
  • mounting the face yarn beam on let-off frames corresponding to two guide bars that control knitting of intermediate connecting yarns on the double-needle-bar warp knitting machine, and enabling the face yarn to be successively threaded through guide needles of the two guide bars that control the knitting of the intermediate connecting yarns on the double-needle-bar warp knitting machine by means of a one-in-one-out threading method;
  • knitting a plush grey fabric with two layers of base fabric and an intermediate U-shaped face yarn on the double-needle-bar warp knitting machine by employing tricot knitting for the ground yarns and modified tricot knitting for the face yarns; and rotating a slitting blade of the plush splitting machine to cut the face yarns of the plush grey fabric to obtain two single-sided plush fabrics, namely, the plush fabric layer.

Further, post-treatment after the plush fabric layer is fabricated includes specific steps as follows:

• • carding the plush fabric layer after cutting through a carding machine; and
  • carrying out luster finishing on the plush fabric layer after carding for three times through a natural luster finishing machine; and
  • pre-setting the plush fabric layer after luster finishing at a high temperature through a setting machine.

Further, specific steps during fabrication of the pattern are as follows:

• • selecting an alloy metal roller that is engraved with the pattern and that has a corresponding size of the roller machine according to a repeat size of a to-be-engraved pattern on the plush fabric layer, and coating the strongly alkaline material onto the metal roller;
  • enabling the plush fabric layer after high-temperature pre-setting to pass through the metal roller of the roller machine at a constant speed with a plush side facing upward, where the pattern on the metal roller is engraved into the plush fabric layer by corrosion of the strongly alkaline material to obtain the pattern; and feeding the plush fabric layer containing the pattern after etching into a drying oven for curing to obtain the plush fabric layer with the pattern.

Further, post-treatment after the pattern is fabricated includes specific steps as follows:

• • feeding the cured plush fabric layer with the pattern into a washing machine for washing;
  • feeding the washed plush fabric layer with the pattern into a dyeing machine for high-temperature dyeing;
  • feeding the plush fabric layer subjected to high-temperature dyeing and provided with the pattern into a washing machine for washing;
  • feeding the plush fabric layer subjected to the second washing and provided with the pattern into a centrifugal hydroextractor for dewatering;
  • feeding the dewatered plush fabric layer with the pattern into a padding machine for softener attachment;
  • feeding the plush fabric layer attached with a softener and provided with the pattern into a centrifugal hydroextractor to remove excess softener;
  • feeding the plush fabric layer subjected to the second dewatering, attached with the softener, and provided with the pattern into a setting machine for high-temperature setting;
  • feeding the plush fabric layer subjected to the second high-temperature setting, attached with the softener, and provided with the pattern into a natural luster finishing machine for luster finishing;
  • feeding the plush fabric layer subjected to the second luster finishing, attached with the softener, and provided with the pattern into a spiral shearing machine for shearing; and
  • feeding the plush fabric layer subjected to shearing, attached with the softener, and provided with the pattern into a lint suction machine for floating lint removal.

Further, specific steps during fabrication of the waterproof layer are as follows: feeding the plush fabric layer subjected to floating lint removal, attached with the softener, and provided with the pattern into a padding machine for water repellent attachment; feeding the plush fabric layer attached with the water repellent and the softener and provided with the pattern into a centrifugal hydroextractor to remove excess water repellent; and feeding the plush fabric layer subjected to third dewatering, attached with water repellent and the softener, and provided with the pattern into a setting machine for high-temperature setting, thereby obtaining the plush fabric layer with the waterproof layer and the pattern.

Compared with the prior art, the present disclosure has beneficial effects as follows.

According to the present disclosure, a roller machine with alloy metal rollers of different sizes is used for engraving. The specific engraving process is as follows: patterns are engraved on the alloy metal rollers of different sizes of the roller machine; according to the repeat size of the engraved pattern, the alloy metal roller of the corresponding size of the roller machine is selected; a strongly alkaline material prepared by stirring caustic soda flakes and paste is coated on the alloy metal roller; the strongly alkaline material on the alloy metal roller is in contact with a single-sided plush fabric, and the pattern on the alloy metal roller is engraved onto the single-sided plush fabric by corrosion. Compared with existing jacquard, plush carving, and embossing processes, the pattern is finer, and the pattern repeat can be enlarged to about 60 mm. In addition, the plush mattress protector features stable product quality, advanced technology, high production efficiency, low cost, and hand feel quality superior to that of products made by conventional processes, and thus is suitable for high-end clothing, home textiles, decorative articles, and beddings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a structure according to the present disclosure;

FIG. 2 is a vertical sectional view according to the present disclosure;

FIG. 3 is an enlarged view of A in FIG. 2 according to the present disclosure.

In the drawings: 1—plush fabric layer; 2—pattern layer; 3—waterproof layer.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following clearly and completely describes the technical solutions in the embodiments of the present disclosure with reference to the accompanying drawings in the embodiments of the present disclosure. Apparently, the described embodiments are merely a part rather than all of the embodiments of the present disclosure. Based on the embodiments in the present disclosure, all other embodiments obtained by those of ordinary skill in the art without making creative labor fall within the scope of protection of the present disclosure.

Embodiment 1

A warping machine, a warp knitting machine equipped with a front needle bed and a rear needle bed as well as six independently electronically controlled guide bars, a plush splitting machine, a carding machine, a natural luster finishing machine, a setting machine, a roller machine equipped with alloy metal rollers of different sizes, a drying oven, a washing machine, a dyeing machine, a centrifugal hydroextractor, a padding machine, a spiral shearing machine, and a lint suction machine are prepared. The six independently electronically controlled guide bars include two guide bars for controlling knitting of a front base fabric, two guide bars for controlling knitting of a rear base fabric, and two guide bars for controlling knitting of intermediate connecting yarns.

Twisted yarns of FDY 68D/24F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarns are sequentially threaded through a tensioner, a leasing needle, a guide roller, and a leasing reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min. The warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 100D/192f semi-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on a creel of the warping machine, the face yarns are sequentially threaded through a tensioner, a leasing needle, a guide roller, and a leasing reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min. The warping machine is started to arrange the face yarns closely and evenly on the beam.

The ground yarn beam of the front base fabric is mounted on a let-off frame corresponding to two guide bars that control the knitting of the front base fabric on the warp knitting machine.

The ground yarns from the ground yarn beam of the front base fabric are sequentially threaded through guide needles of the two guide bars that control the knitting of the front base fabric on the warp knitting machine by means of a non-spaced threading method.

The ground yarn beam of the rear base fabric is mounted on a let-off frame corresponding to two guide bars that control the knitting of the rear base fabric on the warp knitting machine.

The ground yarns from the ground yarn beam of the rear base fabric are sequentially threaded through guide needles of the two guide bars that control the knitting of the rear base fabric on the warp knitting machine by means of a non-spaced threading method.

The face yarn beam of the intermediate connecting yarns is mounted on a let-off frame corresponding to two guide bars that control the knitting of the intermediate connecting yarns on the warp knitting machine.

The face yarns from the face yarn beam of the intermediate connecting yarns are successively threaded through guide needles of the two guide bars that control the knitting of the intermediate connecting yarns by means of a one-in-one-out threading method.

The tension of the ground yarn is to 2.5-3 cN per yarn, and a ground yarn feeding speed is set to 3.5-4 m/min. The tension of the face yarn is set to 1.5-2 cN per yarn, a face yarn feeding speed is set to 3-3.2 m/min. A machine speed is set to 300-320 r/min and a spacing between the needle beds is set to 5 mm. The warp knitting machine is started to knit a grey fabric with two layers of base fabric and intermediate U-shaped face yarns by using a knitting method which employs tricot knitting for the ground yarns and modified tricot knitting for the face yarns.

Tricot knitting means that when a knitting needle is lifted upward, the guide bar swings to the left to lay the ground yarn into a hook of the knitting needle; when the knitting needle moves downward to hook the yarn and form a loop, the guide bar swings to the right in preparation for the next yarn laying, and the cycle of “left swing for yarn laying→right swing for resetting” is repeated to form a continuous tricot stitch loop structure.

There are four cycles for the modified tricot knitting. In the first cycle, that is, during yarn laying of the front needle bed, when the knitting needle is lifted upward, the guide bar swings to the left while remaining on the front needle bed side, the face yarn is laid into a hook of a knitting needle on the front needle bed, and then the knitting needle moves downward to hook the yarn to form a front-side loop. In the second cycle, that is, during resetting, the guide bar swings to the right to return to a middle position while remaining stationary in a front-back direction. In the third cycle, that is, during the yarn laying of the front needle bed again, when the knitting needle is lifted upward once more, the guide bar swings to the left to continuously lay the face yarn into a hook of an adjacent knitting needle on the front needle bed, thereby forming a second front-side loop. In the fourth cycle, that is, during yarn laying of the rear needle bed, when the knitting needle is lifted upward, the guide bar swings to the right and moves backward by 5 mm to reach the rear needle bed side, the face yarn is laid into a hook of a knitting needle on the rear needle bed, and then the knitting needle moves downward to hook the yarn to form a rear-side loop. By repeating the foregoing four cycles, the face yarns can form continuous “U-shaped loops” between the front needle bed and the rear needle bed, with each U-shaped loop spanning the two layers of base fabric and firmly connecting the front and rear base fabrics.

The knitted grey fabric is fed into a plush splitting machine, where a fabric feeding speed is set to 15-20 m/min and a rotation speed of a slitting blade is set to 4000 r/min. The plush splitting machine is started, the slitting blade rotates to cut the face yarns to form two single-sided plush fabrics with a height of 3 mm, namely, the plush fabric layer 1.

The cut single-sided plush fabric is fed into a carding machine, where a fabric feeding speed is set to 18.3 m/min, and a rotation speed is set to 1000 r/min. The carding machine is started, and needle rollers of the carding machine are configured to comb along a direction of the plush, which makes the plush neat and upright simultaneously while removing impurities.

The single-sided plush fabric after carding is fed into the natural luster finishing machine with a plush side facing upward, where a fabric feeding speed is set to 20 m/min and a temperature of a hot roller is set to above 190° C. The natural luster finishing machine is started, and the single-sided plush fabric passes uniformly between the hot roller and a rubber roller of the natural luster finishing machine. The plush side of the single-sided plush fabric is in contact with the hot roller, and heat of the hot roller is transferred to the plush side of the single-sided plush fabric to soften the plush side.

The single-sided plush fabric after luster finishing is fed into a setting machine, where a fabric feeding speed is set to 50 mm/min and a temperature is set to 200° C. The setting machine is started to perform high-temperature pre-setting on the single-sided plush fabric.

According to a repeat size of the engraved pattern, an alloy metal roller of a corresponding size of the roller machine is selected; a strongly alkaline material prepared by stirring caustic soda flakes and paste is coated on the alloy metal roller; the single-sided plush fabric after high-temperature pre-setting is fed into the roller machine, where a fabric feeding speed is set to 50 mm/min. The roller machine is started, so that the pattern on the alloy metal roller can be engraved onto the plush fabric layer by corrosion of the strongly alkaline material on the alloy metal roller.

The single-sided plush fabric after engraving is fed into a drying oven, where a fabric feeding speed is set to 10 m/min and a temperature is set to 180° C. The drying oven equipment is started for baking.

The baked single-sided plush fabric with a pattern is fed into the washing machine, where a mass ratio of a washing agent to water to 1:10, a stirring speed is set to 30-40 r/min, and dewatering speed is set to 600-800 r/min. The washing machine is started for washing to remove floating lint.

The washed single-sided plush fabric with the pattern is fed to the dyeing machine, where a preheating stage is set to have temperature rise at a rate of 2° C./min to 80° C. and then hold the temperature for 10 min; a high-temperature dyeing stage is set to have a temperature rise at a rate of 1° C./min to 130-135° C., increase the pressure to 2.5-3 atm, and hold the temperature for 35-40 min, and a cooling stage is set to have temperature drop at a rate of 3° C./min to room temperature, followed by pressure release and dyeing waste liquor discharge. The dyeing machine is started to perform high-temperature dyeing.

The singled-sided plush fabric subjected to high-temperature dyeing and provided with the pattern is fed into a washing machine, where a mass ratio of a washing agent to water is set to 1:10, a stirring speed is set to 30-40 r/min, and a dewatering speed is set to 600-800 r/min. The washing machine is started to perform washing, and the washing is repeated until the discharged waste liquor is clear and free of floating color.

The single-sided plush fabric subjected to the second water washing and provided with the pattern is fed into a centrifugal hydroextractor, where a rotation speed is set to 800-1000 r/min. The centrifugal hydroextractor is started for dewatering.

The dewatered single-sided plush fabric with the pattern is fed into a padding machine, where a mass ratio of a softener to water is set to 1:20, a fabric feeding speed is set to 10 m/min, and a pressure of the rolling roller is set to 0.05-0.1 MPa. The padding machine is started to make the softener evenly attached to the single-sided plush fabric with the pattern.

The single-sided plush fabric attached with the softener and provided with the pattern is fed into a centrifuge hydroextractor, where a rotation speed is set to 800-1000 r/min. The centrifuge hydroextractor is started to remove excess softener.

The single-sided plush fabric subjected to the second dewatering, attached with the softener, and provided with the pattern is fed into a setting machine, where a fabric feeding speed is set to 50 mm/min and a temperature is set to 180° C. The setting machine is started to perform high-temperature setting on the single-sided plush fabric.

The single-sided plush fabric subjected to the second high-temperature setting, attached with the softener, and provided with the pattern is fed into a natural luster finishing machine, where a fabric feeding speed is set to 15-20 m/min and a temperature of a hot roller is set to above 190° C. The natural luster finishing machine is started, and the single-sided plush fabric attached with the softener and provided with the pattern passes uniformly between the hot roller and a rubber roller of the natural luster finishing machine, and a plush side of the single-sided plush fabric attached with the softener and provided with the pattern is in contact with the hot roller, and the heat of the hot roller is transferred to the plush side of the single-sided plush fabric attached with the softener and provided with the pattern to soften the plush side thereof.

The single-sided plush fabric subjected to the second luster finishing, attached with the softener, and provided with the pattern is fed into a spiral shearing machine, where a fabric feeding speed is set to 8-10 m/min, the tension is set to 2-3 N/m, and a scissors speed is set to 2400-2600 r/min. The spiral shearing machine is started for shearing.

The shorn single-sided plush fabric attached with the softener and provided with the pattern is fed into a lint suction machine, where an air speed is set to 8-10 m/s. The lint suction machine is started to remove floating lint, thereby obtaining the plush fabric layer 1 with the pattern 2.

The single-sided plush fabric subjected to floating lint removal, attached with the softener, and provided with the pattern is fed into a padding machine, where a mass ratio of a water repellent to water is set to 1:20, a fabric feeding speed is set to 10 m/min, and a pressure of a rolling roller is set to 0.05-0.1 MPa. The padding machine is started to make the water repellent evenly attached to the single-sided plush fabric attached with the softener and and provided with the pattern.

The single-sided plush fabric attached with the water repellent and the softener and provided with the pattern is fed into a centrifugal hydroextractor, where a rotation speed is set to 800-1000 r/min. The centrifugal hydroextractor is started to remove excess water repellent.

The single-sided plush fabric subjected to the third dewatering, attached with the water repellent and the softener, and provided with the pattern is fed into a setting machine, where a fabric feeding speed is set to 50 mm/min and a temperature is set to 180° C. The setting machine is started to perform high-temperature setting on the single-sided plush fabric, thereby obtaining the plush fabric cloth 1 with the pattern 2 and the waterproof layer 3.

The single-sided plush fabric subjected to the third high-temperature setting, attached with the water repellent and the softener, and provided with the pattern is sewn together with an elastic band to form a mattress protector.

Embodiment 2

This embodiment is different from Embodiment 1 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 100D/192f semi-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Embodiment 3

This embodiment is different from Embodiment 2 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 100D/192f full-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Embodiment 4

This embodiment is different from Embodiment 3 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 120D/192f semi-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Embodiment 5

This embodiment is different from Embodiment 3 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 120D/192f full-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Embodiment 6

This embodiment is different from Embodiment 3 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 150D/288f semi-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Embodiment 7

This embodiment is different from Embodiment 3 in that:

Twisted yarns of 75D/36F polyester filament yarns and carbon fiber conductive yarns are used as ground yarns; a spool for the ground yarns is placed on a creel of the warping machine, the ground yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 2.5-3 cN per yarn, and a yarn feeding speed is set to 300-350 m/min, and the warping machine is started to arrange the ground yarns closely and evenly on the beam.

Twisted yarns of 150D/288f full-dull DTY and carbon fiber conductive yarns are used as face yarns; a spool for the face yarns is placed on the creel of the warping machine, the face yarn is sequentially threaded through a tensioner, a lease needle, a guide roller, and a lease reed on the creel of the warping machine before being wound onto an empty beam. The tension is set to 1.5-2 cN per yarn, and a yarn feeding speed is set to 280-320 m/min, and the warping machine is started to arrange the face yarns closely and evenly on the beam.

Although the embodiments of the present disclosure have been shown and described, those of ordinary skill in the art may understand that many changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and purposes of the present disclosure, and the scope of the present disclosure is defined by the claims and their equivalents.