Warp-knitted one-piece fleece fabric and its preparation method

Abstract

The present invention relates to the technical field of plush fabrics and their preparation, and particularly relates to a warp-knitted integrated plush fabric and a preparation method thereof. The plush fabric includes a first plush layer, a second plush layer, and a connecting layer located between the first plush layer and the second plush layer. The first plush layer includes a front comb extension line layer, which is formed by processing the extension lines of the front comb. The connecting layer sequentially includes a middle comb extension line layer, a back comb extension line layer, a middle comb coil layer, and a front comb coil layer from the first plush layer to the second plush layer. Each layer is formed by the common interlacing of the extension lines of the middle comb, the extension lines of the back comb, the coils of the middle comb, and the coils of the front comb in sequence. The second plush layer includes a back comb coil layer, a back comb extension line layer, or a combined layer of both. The preparation method includes yarn warping, machine knitting, and dyeing and finishing. The present invention can form various variable structures, and at the same time, the respective types and colors of the plush on the front and back can be independently selected and freely combined according to the design and requirements, forming many style effects.

Description

Technical Field

[0001] The present invention relates to the technical field of plush fabrics and their preparation, and particularly relates to a warp-knitted integrated plush fabric and a preparation method thereof. Background Art

[0002] With the development of society and the progress of technology, people's requirements for the quality of fabrics used in clothing and home textiles are also getting higher and higher. As a major category of products in autumn and winter clothing and home textiles, plush products have rich variations and wide applications. People not only satisfy the appearance beauty, comfort, warmth, etc. of plush products, but also pay more and more attention to their environmental protection, diversity, and use safety, etc.

[0003] In recent years, the "integrated plush" fabric and products have emerged in the market and been popular for a while. The so-called "integrated plush" mainly refers to a double-sided plush in which two fabrics can be directly combined into one without being compounded, also known as "non-compounded" plush. Since there is no need for compounding processing, it avoids the harm caused by chemical substances such as glue and the problem that the glue is easy to debond during use, thus causing the two sides of the fabric to separate. Thereby, the use safety and durability of the product are improved. At present, most of the integrated plush fabrics on the market are weft-knitted structures. For example, a kind of fur-like integrated fabric and production process introduced in Patent CN 112593336 A is made by using a weft-knitted double-sided machine structure. The front side of the fur-like integrated fabric is made of 222 dtex / 96F polyester filament, and the back side is made of 21 SJC, the intermediate connecting yarn uses 83dtex / 36F polyester filament, and then it is processed through the conventional plush dyeing and finishing process to form a double-sided integrated fabric with a cotton plain cloth structure on one side and a polyester plush structure on the other side. Since a weft knitting double-sided machine is used, this machine can itself weave different weft knitted fabrics on both sides respectively, but the knitting efficiency is very low, and the weft knitting structure is prone to unraveling. The two sides are only connected by a single polyester filament, and the connection strength between the two sides is not high. In addition, the structure that can only form a plain cloth on one side and plush on the other side is also very limited. For another example, Patent CN 114737305 A proposes an integrated cut pile fabric, which includes a knitted structure and several yarn groups woven into the knitted structure. The yarn group includes a backing yarn and a pile yarn that forms loops on one side of the knitted structure. The backing yarn presses the pile yarn, and the loops are formed into cut pile through shearing treatment. From the perspective of the structural essence, it still belongs to a weft knitted cut pile product, and there are still problems such as low knitting efficiency, easy unraveling of the structure, and the weft plain stitch structure itself is relatively loose and not dense enough. Relying on the backing yarn (or called "tying wire") to press the pile yarn, it is also very difficult to avoid the problem of hair loss. In addition, the structure of this kind of fabric is relatively fixed, lacking flexibility and variability, and it is also very difficult to achieve a wide width or even an extra-wide width to meet the home textile use. For another example, Patent CN 107460619 A discloses a production method of short hair flannel, that is, pulling the plush part on the front side of the warp knitted single-sided flannel to the back side to form a double-sided plush fabric. In this way, the material, pile height, and style of the plush on the back side of the fabric can only depend on the plush on the front side, resulting in a single and similar pile feeling on both sides of the fabric, lacking creativity. Moreover, during the process of pulling the front plush to the back side, the fullness of the front plush is reduced, and this raising process is likely to damage the loop structure and root fibers of the front plush, thus causing the problem of hair loss.

[0004] Therefore, there is an urgent need for a warp knitted integrated plush fabric for double-sided integrated plush, which has high knitting production efficiency, large differences, many changes, and small limitations in the plush styles on the front and back sides, a stable structure that is not prone to unraveling, the fabric fluff is not easy to fall off, does not require lamination, is safe and environmentally friendly, durable, and suitable for uses such as clothing and home textiles, and its preparation method.

[0005] The existing plush fabrics have the following technical problems:

[0006] 1. The structure of the weft knitted integrated plush fabric is relatively single, the variability between the front and back sides is not strong, the structure is not stable enough, prone to unraveling and hair loss, and it also requires a special cut pile machine for production, with low production efficiency, and it is also difficult to meet the requirements of wide width or even extra-wide width, etc.

[0007] 2. Due to the limitation of the inherent structure, the plush on the front and the base fabric on the back of warp knitted plush products are made of the same yarn raw material, and the back cannot be used directly, but needs to be compounded or napped. For napping, the plush part on the front (about 40%) is pulled to the back. In essence, the material, height and style of the plush on the back can only depend on the plush on the front. The plush on the front and back affect each other, and the two cannot be formed and processed independently, resulting in a single and similar plush feel on the front and back of the fabric, lacking creativity, and reducing the fullness of the plush on the front. In the process of pulling the plush from the front to the back, it passes through the base fabric, which will damage the fabric structure and fibers, thereby aggravating hair loss. Summary of the invention

[0008] In order to solve the above technical problems, the present invention provides a warp-knitted integrated velvet fabric, comprising a first velvet layer, a second velvet layer, and a connecting layer located between the first velvet layer and the second velvet layer;

[0009] The first plush layer includes a front comb extension line layer, which is formed by processing the front comb extension line;

[0010] The connecting layer includes a middle comb extension line layer, a back comb extension line layer, a middle comb coil layer and a front comb coil layer in sequence from the first plush layer to the second plush layer, and each layer is formed by interlacing the middle comb extension line, the back comb extension line, the middle comb coil and the front comb coil in sequence;

[0011] The second plush layer includes a back-combed coil layer, a back-combed extension line layer or a combination of the two, wherein the back-combed coil layer is formed by processing back-combed coils, the back-combed extension line layer is formed by processing back-combed extension lines, and the combination layer is formed by processing back-combed coils and extension lines.

[0012] Optionally, the front comb adopts N+1 needle closed warp plain weave, and the inlay yarn is digitally recorded as: 1-0 / N-(N+1) / / (N≥15);

[0013] or,

[0014] The front comb uses two N+1 needles and P+1 needles in the same direction for closed warp plain weave, and the inlay yarn numbers are recorded as: 1-0 / N-(N+1) / / (N≥15) and 1-0 / P-(P+1) / / (P≤10) respectively.

[0015] Optionally, the middle comb adopts L+1 needle closed warp plain weave, and the lapping yarn is digitally recorded as: L-(L+1) / 1-0 / / (1≤L≤3);

[0016] or,

[0017] The middle comb uses two reverse L + 1 - needle closed - end plain - knitting structures. The guide bar notations are respectively recorded as: L-(L + 1) / 1 - 0 / / (1 ≤ L ≤ 3) and 1 - 0 / L-(L + 1) / / (1 ≤ L ≤ 3).

[0018] Optionally, the back comb uses an M + 1 - needle open - end plain - knitting structure, and the guide bar notation is recorded as: 0 - 1 / (M + 1)-M / / (2 ≤ M ≤ 5);

[0019] Or,

[0020] the back comb uses an M - needle weft - insertion structure, and the guide bar notation is recorded as: M - M / 0 - 0 / / (2 ≤ M ≤ 5);

[0021] Or,

[0022] the back comb uses an M + 1 - needle open - end plain - knitting structure, and the guide bar notation is recorded as: (M + 1)-M / 0 - 1 / / (2 ≤ M ≤ 5);

[0023] Or,

[0024] the back comb uses two reverse M + 1 - needle open - end plain - knitting structures, and the guide bar notations are respectively recorded as: 0 - 1 / (M + 1)-M / / (2 ≤ M ≤ 5) and (M + 1)-M / 0 - 1 / / (2 ≤ M ≤ 5); or the back comb uses two reverse M - needle weft - insertion structures, and the guide bar notations are respectively recorded as: 0 - 0 / M - M / / (2 ≤ M ≤ 5) and M - M / 0 - 0 / / (2 ≤ M ≤ 5); or the back comb uses one M + 1 - needle open - end plain - knitting structure and one M - needle weft - insertion structure, and the guide bar notations are respectively recorded as: 0 - 1 / (M + 1)-M / / and 0 - 0 / M - M / / (2 ≤ M ≤ 5).

[0025] Optionally, the front comb selects 75 - 300D polyester DTY round - hole low - elastic yarn, and the single - filament fineness range is 0.52 - 1.04D, or 75 - 300D polyester FDY flat - cross - section filament, and the single - filament fineness range is 1.04 - 4.16D;

[0026] The middle comb selects 50 - 100D polyester FDY or DTY ordinary polyester filament, and the actual warp - feeding amount of the middle comb is 0.85 - 0.95 times of the calculated warp - feeding amount;

[0027] The back comb selects 75 - 300D polyester DTY round - hole low - elastic yarn, and the single - filament fineness range is 0.52 - 1.04D; or selects one of 75 - 300D polyester sea - island yarn, solution - dyed polyester filament, Lyocell filament and mulberry silk; the actual warp - feeding amount of the back comb is 1.5 - 3 times of the calculated warp - feeding amount.

[0028] The present invention also provides a preparation method of the above - mentioned warp - knitted fleece fabric, including the following steps:

[0029] S100: Determine the raw material of the yarn for knitting, and warp the yarn using the selected warping machine;

[0030] S200: Use a warp knitting machine equipped with no less than three combs. Divide the combs into three groups for knitting with the front comb, middle comb, and rear comb respectively, and perform knitting on the machine:

[0031] A. Threading: Front comb: 1 thread through and 1 space; Middle comb: full threading; Rear comb: full threading;

[0032] B. Knitting: Perform the knitting process according to the following warp feeding amounts:

[0033] Front comb: The guide bar notation is 1-0 / 17-18 / / , and the actual warp feeding amount used is 0.9 - 1.1 times the calculated warp feeding amount;

[0034] Middle comb: The guide bar notation is 1-2- / 1-0 / / , and the actual warp feeding amount used is 0.85 - 0.95 times the calculated warp feeding amount;

[0035] Rear comb: The guide bar notation is 0-1 / 3-4 / / , and the actual warp feeding amount used is 1.5 - 3 times the calculated warp feeding amount;

[0036] The pulling density used for knitting ranges from 13 to 20 cpc, and the starting speed ranges from 1500 - 2200 rpm;

[0037] S300: Perform dyeing and finishing on the knitted greige fabric to obtain a warp-knitted fleece fabric.

[0038] Optionally, in step S200, before knitting on the machine, adjust the tension compensation device of the rear comb, that is, extend the tension rod of the tension compensation device of the rear comb forward by 15 - 35 cm; and use a tension spring with a tension sensitivity of not less than 0.1 cN for the tension compensation device of the rear comb.

[0039] Optionally, in step S100, the yarn warping method is as follows:

[0040] Front comb: Use an SGZ400D intelligent computer-controlled warping machine, beam specification: Φ21×21”; number of warp ends: 293; number of warping beams: 8; warping speed: 1200 rpm; warping tension: 8 - 9 cN;

[0041] Middle comb: Use an SGZ300D computer-controlled high-speed warping machine, beam specification: Φ21×21”; number of warp ends: 588; number of warping beams: 8; warping speed: 1500 rpm; warping tension: 5 - 6 cN;

[0042] Back comb: Use SGZ400D intelligent computer-controlled warping machine, beam specifications: Φ21×21”; number of warp ends: 588; number of warping beams: 8; warping speed: 1200 rpm; warping tension: 8 - 9 cN.

[0043] Optionally, in step S300, the dyeing and finishing process includes:

[0044] Perform pre-setting on the back side of the grey cloth, back napping or sanding, and back shearing on the second plush layer side in sequence;

[0045] Perform pre-setting on the front side of the grey cloth, front napping, and front calendering on the first plush layer side in sequence;

[0046] Perform dyeing, washing and softening, drying, and hot air blowing on the first plush layer side and the second plush layer side after the previous processing in sequence; then perform front ironing and shearing on the first plush layer side, and back shearing on the second plush layer side; finally, perform polar fleece processing on the grey cloth and fabric rolling.

[0047] Optionally, during the knitting process, for the knitting yarn, use a CCD camera to take images of the yarn feeding and perform vibration detection on the knitting machine;

[0048] Distinguish each single yarn through image recognition. According to the feeding distance of each single yarn and the detected vibration data of the knitting machine, use simulation technology to perform vibration transfer simulation analysis on each single yarn to obtain the vibration data of each point of each single yarn within the feeding distance; the vibration data includes vibration amplitude;

[0049] Use machine vision recognition technology to perform image preprocessing on the captured real-time image, distinguish each single yarn through image recognition, combine with the vibration data of the corresponding single yarn, and perform image analysis on each single yarn to obtain the linear diameter data of each point of the single yarn fed in real time;

[0050] Compare the linear diameter data with the upper limit threshold and the lower limit threshold of the linear diameter of the corresponding single yarn. If the linear diameter data deviates from the linear diameter range defined by both the upper limit threshold and the lower limit threshold of the linear diameter, a warning message is issued.

[0051] The warp-knitted one-piece fleece fabric of the present invention and its preparation method can be diversely combined to achieve a differential appearance effect of "fur" on the front and "fleece" on the back. The styles on both sides can be independent of each other and do not affect each other. Moreover, by combining the selection of yarn raw materials and the adjustment of post-finishing processes, the possibility of extending various style variations can be achieved. For example, on the front, appearance effects such as A imitation rabbit hair, B imitation mink hair, C imitation wool, D milk fleece, E polar fleece, etc. can be formed, and on the back, appearance effects such as V imitation suede, W imitation polar fleece, X imitation orlon fleece, Y imitation corduroy, Z imitation chenille fluff, etc. can be formed. Among them, A-E and V-Z can be randomly combined to form various variable structures. At the same time, the respective colors of the plush systems on the front and back can also be independently selected and freely combined, and many style effects can also be formed from the color aspect, unlike the traditional fabric structure which is subject to certain restrictions or results in the same front and back effects, lacking creativity, etc.

[0052] Other features and advantages of the present invention will be described in the subsequent description, and, in part, will be obvious from the description or will be understood by implementing the present invention. The objectives and other advantages of the present invention can be realized and obtained by the structures specifically pointed out in the written description and the drawings.

[0053] The technical solutions of the present invention will be further described in detail below through the drawings and embodiments. Description of the Drawings

[0054] The drawings are used to provide a further understanding of the present invention and constitute a part of the description. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation to the present invention. In the drawings:

[0055] Figure 1 is a schematic cross-sectional structure diagram of a warp-knitted one-piece fleece fabric in an embodiment of the present invention;

[0056] Figure 2 is a schematic knitting structure diagram of the warp-knitted one-piece fleece fabric embodiment of the present invention;

[0057] Figure 3 is a schematic flow diagram of the preparation method of a warp-knitted one-piece fleece fabric in an embodiment of the present invention;

[0058] Figure 4 is a schematic flow diagram of an application case of the preparation method of a warp-knitted one-piece fleece fabric in an embodiment of the present invention;

[0059] Figure 5 is a schematic shape diagram of an application case of the preparation method of a warp-knitted one-piece fleece fabric in an embodiment of the present invention during the knitting process on a loom;

[0060] Figure 6 is a schematic shape diagram of an application case of the preparation method of a warp-knitted one-piece fleece fabric in an embodiment of the present invention during the dyeing and finishing process. Specific Embodiments

[0061] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only for the purpose of illustrating and explaining the present invention, and are not intended to limit the present invention.

[0062] As Figure 1-2 shown, the embodiment of the present invention provides a warp-knitted fleece fabric, which includes a first plush layer 1, a second plush layer 3, and a connecting layer 2 located between the first plush layer 1 and the second plush layer 3;

[0063] The first plush layer 1 includes a front comb extension line layer, which is formed by processing the extension lines of the front comb;

[0064] The connecting layer 2 sequentially includes a middle comb extension line layer 21, a back comb extension line layer 22, a middle comb coil layer 23, and a front comb coil layer 24 from the first plush layer 1 to the second plush layer 3. Each layer is formed by the common interlacing of the extension lines of the middle comb, the extension lines of the back comb, the coils of the middle comb, and the coils of the front comb in sequence;

[0065] The second plush layer 3 includes a back comb coil layer, a back comb extension line layer, or a combined layer of both. The back comb coil layer is formed by processing the coils of the back comb, the back comb extension line layer is formed by processing the extension lines of the back comb, and the combined layer is formed by processing the coils and extension lines of the back comb.

[0066] The working principle and beneficial effects of the above technical solution are as follows: The warp-knitted single-sided fleece fabric of this solution can be formed by knitting with a three-bar ordinary tricot warp knitting machine or a four-bar ordinary tricot warp knitting machine. The structure of the warp-knitted single-sided fleece fabric includes a first plush system (i.e., the first plush layer) on the front, a second plush system (i.e., the second plush layer) on the back, and a connecting system (i.e., the connecting layer) in the middle. The warp-knitted single-sided fleece fabric is formed by knitting at least one front bar, one back bar, and one middle bar. The first plush system is formed by processing the extended yarns of the front bar. The second plush layer can include a back bar coil layer or (part of) a back bar extended yarn layer. The second plush layer can also be a combined layer of a back bar coil layer and a back bar extended yarn layer. Specifically, there are the following situations: a. The back bar is one bar (forming loops), and this bar forms the back bar coil layer; b. The back bar is one bar (weft insertion), and this bar forms (part of) the back bar extended yarn layer; c. The back bar is two bars, and both bars are forming loops, and both of these two bars form the back bar coil layer; d. The back bar is two bars, and both bars are weft insertion. The weft insertion structure only has extended yarns and no loops, and both of these two back bars form (part of) the back bar extended yarn layer; e. The back bar is two bars, one for weft insertion and one for forming loops, and these two bars form (part of) the back bar extended yarn layer and the back bar coil layer, which are formed by processing the coils or part of the extended yarns of the back bar. Among them, the first plush system and the second plush system are independent of each other and do not affect each other. The cross-sectional structure of the warp-knitted single-sided fleece fabric during knitting includes at least the following six hierarchical relationships from the front to the back: front bar extended yarn, middle bar extended yarn, back bar extended yarn, middle bar coil, front bar coil, back bar coil. And during the subsequent processing, the relative hierarchical position relationship of the cross-sectional structure of the single-sided fleece fabric always remains unchanged. This warp-knitted plush structure breaks through the inherent plush structure of the traditional warp knitting process (the cross-sectional structure from the front to the back is successively the front bar extended yarn, middle bar extended yarn, back bar extended yarn, back bar coil, middle bar coil, front bar coil, that is, the back bar is clamped in the core layer and is successively "wrapped" by the extended yarns and coil layers of the middle bar and the front bar), realizing an innovative change in the relative positions and hierarchical relationships of the front bar, middle bar, and back bar of the plush fabric, thereby establishing a structural basis for forming the warp-knitted single-sided fleece fabric.The warp-knitted one-piece fleece fabric of this solution can be diversifiedly combined to achieve a differential appearance effect of "fur" on the front and "fleece" on the back. The styles on both sides can be independent of each other without affecting each other, and by combining the selection of yarn raw materials and the adjustment of post-finishing processes, the possibility of various style changes can be extended. For example, on the front, appearance effects such as A imitating rabbit hair, B imitating mink hair, C imitating wool, D milk fleece, E Arctic fleece, etc. can be formed, and on the back, appearance effects such as V imitating suede, W imitating polar fleece, X imitating oly fleece, Y imitating corduroy, Z imitating chenille fluff, etc. can be formed. Among them, A - E and V - Z can be randomly combined to form various variable structures. At the same time, the respective colors of the plush systems on the front and back can also be independently selected and freely combined, and many style effects can also be formed from the color aspect, without being restricted like traditional fabric structures or causing the same effects on the front and back, lacking creativity, etc.

[0067] In one embodiment, the front comb adopts an N + 1 - needle closed - warp - plain stitch, and the laying - in notation is recorded as: 1 - 0 / N-(N + 1) / / (N is a positive integer and N≥15); for example, the laying - in notation is 1 - 0 / 17 - 18 / / ;

[0068] Or,

[0069] The front comb adopts two same - direction N + 1 - needle and P + 1 - needle closed - warp - plain stitches, and the laying - in notations are respectively recorded as: 1 - 0 / N-(N + 1) / / (N≥15) and 1 - 0 / P-(P + 1) / / (P≤10).

[0070] The working principle and beneficial effects of the above - mentioned technical solution are as follows: By further defining the knitting structure form (warp - plain stitch) of the front comb, for the production of fleece fabric products, the operability and guidance in the production process are enhanced, which is beneficial to the standardization of production, beneficial to the quality control and management of products, and beneficial to improving production efficiency.

[0071] In one embodiment, the middle comb adopts an L + 1 - needle closed - warp - plain stitch, and the laying - in notation is recorded as: L-(L + 1) / 1 - 0 / / (1≤L≤3); for example, the laying - in notation is 1 - 2 - / 1 - 0 / / ;

[0072] Or,

[0073] The middle comb adopts two reverse L + 1 - needle closed - warp - plain stitches, and the laying - in notations are respectively recorded as: L-(L + 1) / 1 - 0 / / (1≤L≤3) and 1 - 0 / L-(L + 1) / / (1≤L≤3).

[0074] The working principle and beneficial effects of the above - mentioned technical solution are as follows: By further defining the knitting structure form (warp - plain stitch) of the middle comb, for the production of fleece fabric products, the operability and guidance in the production process are enhanced, which is beneficial to the standardization of production, beneficial to the quality control and management of products, and beneficial to improving production efficiency.

[0075] In one embodiment, the back comb adopts a M+1-needle open plain stitch, and the yarn laying digital notation is: 0-1 / (M+1)-M / / (2≤M≤5); for example, the yarn laying digital notation is 0-1 / 4-3 / / ;

[0076] Or,

[0077] the back comb adopts a M-needle weft insertion stitch, and the yarn laying digital notation is: M-M / 0-0 / / (2≤M≤5);

[0078] Or,

[0079] the back comb adopts a M+1-needle open plain stitch, and the yarn laying digital notation is: (M+1)-M / 0-1 / / (2≤M≤5);

[0080] Or,

[0081] the back comb adopts two reverse M+1-needle open plain stitches, and the yarn laying digital notations are respectively: 0-1 / (M+1)-M / / (2≤M≤5) and (M+1)-M / 0-1 / / (2≤M≤5); or, the back comb adopts two reverse M-needle weft insertion stitches, and the yarn laying digital notations are respectively: 0-0 / M-M / / (2≤M≤5) and M-M / 0-0 / / (2≤M≤5); or, the back comb adopts one M+1-needle open plain stitch and one M-needle weft insertion stitch, and the yarn laying digital notations are respectively: 0-1 / (M+1)-M / / and 0-0 / M-M / / (2≤M≤5).

[0082] The working principle and beneficial effects of the above technical solution are: by further defining the knitting structure form of the back comb (plain stitch or weft insertion stitch), the actual organizational structure is not limited to the above structure. On this basis, the knitting process and organizational structure are adjusted, such as changing the loop-forming structure to a weft insertion structure, changing the open coil to a closed coil, changing the value range of M needles, etc. These should all be regarded as within the protection scope of this technical invention; for the production of plush fabric products, it enhances the operability and guidance during the production process, is conducive to production standardization, is conducive to product quality control and management, and is conducive to improving production efficiency.

[0083] In one embodiment, the front comb selects 75-300D polyester DTY round-hole low-elastic yarn, and the single-filament fineness range is 0.52-1.04D, or 75-300D polyester FDY flat-section filament, and the single-filament fineness range is 1.04-4.16D; wherein, D is the fiber fineness unit "denier" or "denier number" (i.e., Denier, Daniel);

[0084] The middle comb selects 50-100D polyester FDY or DTY ordinary polyester filament, and the actual warp feeding amount of the middle comb is 0.85-0.95 times of the calculated warp feeding amount;

[0085] The back comb selects 75 - 300D polyester DTY round hole low - elastic yarn, and the single - filament fineness range is 0.52 - 1.04D; or one of 75 - 300D polyester sea - island yarn, solution - dyed polyester filament, Lyocell filament and mulberry silk. The actual warp feeding amount of the back comb is 1.5 - 3 times of the calculated warp feeding amount.

[0086] The working principle and beneficial effects of the above - mentioned technical solution are as follows: This solution further defines the adopted yarn raw materials and feeding parameters (warp feeding amount). For the production of plush fabric products, it enhances the operability and guidance in the production process, is conducive to the standardization of production, is conducive to the quality control and management of products, and is conducive to improving production efficiency. Among them, the warp feeding amount refers to the length of the warp yarn for sending out 480 coil courses (including coils and extension yarns) (generally in mm). The warp feeding amount is related to factors such as the machine model, knitting structure, and vertical density of the coils. The calculated warp feeding amount can be obtained through theoretical calculation. In the prior art, the actual warp feeding amount generally used does not deviate much from the calculated warp feeding amount. The calculated warp feeding amount is also called the theoretical warp feeding amount, which is obtained through theoretical calculation. Usually, the operator will input the theoretical warp feeding amount into the warp knitting machine for debugging the machine. Before knitting, the warp feeding amount will be adjusted according to the actual knitting situation, but usually it is a small - range adjustment, that is, the deviation from the theoretical warp feeding amount does not exceed ±10%. In this solution, the actual warp feeding amount of the front comb is selected to be less than the calculated warp feeding amount, while the actual warp feeding amount of the back comb is selected to be much greater than the calculated warp feeding amount. Thus, on the basis of the plush fabric structure, it further realizes the protection of the structural optimization and process refinement, that is, the processes (structural parameters such as knitting structure, yarn laying process, coil opening / closing form, and relationship of warp feeding amount) of the front, middle, and back combs are defined and protected.

[0087] As Figure 2 shown, the present invention also provides a preparation method for the above - mentioned warp - knitted integrated plush fabric, including the following steps:

[0088] S100: Determine the yarn raw materials for knitting and carry out yarn warping using the selected warping machine.

[0089] S200: Use a warp knitting machine equipped with no less than three guide bars. Divide the guide bars into three groups, which are respectively responsible for the knitting of the front comb, middle comb, and back comb, and carry out knitting on the machine:

[0090] For example: Use a common Terry - cloth warp knitting machine (machine number: E28) equipped with no less than three guide bars (such as three or four). Divide the guide bars into three groups, which are respectively responsible for the knitting of the front comb, middle comb, and back comb. For example, if there are four guide bars, then one of the groups responsible for the front comb, middle comb, and back comb is composed of two guide bars; the machine width of the warp knitting machine: 210 inches.

[0091] A. Warp threading: Front comb GB1: 1 warp thread through 1 space; Middle comb GB2: full threading; Rear comb GB3: full threading;

[0092] B. Weaving:

[0093] Carry out according to the following weaving process

[0094] Front comb GB1: The actual warp let-off amount used is 0.9 - 1.1 times the calculated warp let-off amount; For example: The calculated warp let-off amount is 8350 mm / rack, and the actual warp let-off amount is 8360 mm / rack;

[0095] Middle comb GB2: The actual warp let-off amount used is 0.85 - 0.95 times the calculated warp let-off amount; For example: The calculated warp let-off amount is 1360 mm / rack, and the actual warp let-off amount is 1200 mm / rack;

[0096] Rear comb GB3: The actual warp let-off amount used is 1.5 - 3 times the calculated warp let-off amount; For example: The calculated warp let-off amount is 2230 mm / rack, and the actual warp let-off amount is 4200 mm / rack;

[0097] The take-up density used for weaving ranges from 13 - 20 cpc. For example, the take-up density for weaving can be 16.5 cpc, and the starting speed ranges from 1500 - 2200 rpm; For example, the starting speed can be 1800 rpm; That is, the take-up density and the starting speed are fixed values, and both of these two parameters need to be set on the machine in advance during actual weaving;

[0098] S300: Carry out dyeing and finishing on the woven grey fabric to obtain warp-knitted fleece fabric.

[0099] The working principle and beneficial effects of the above technical solution are as follows: The warp knitting integrated fleece fabric preparation method of this solution can achieve diversified combinations, realizing the differential appearance effect of "fur" on the front side and "fleece" on the back side of the fleece fabric. The styles of the two sides can be independent of each other and do not affect each other. Moreover, by combining the selection of yarn raw materials and the adjustment of post-finishing processes, the possibility of various style changes can be extended. For example, on the front side, appearance effects such as A imitating rabbit hair, B imitating mink hair, C imitating wool, D milk fleece, E polar fleece, etc. can be formed, and on the back side, appearance effects such as V imitating suede, W imitating polar fleece, X imitating oly fleece, Y imitating corduroy, Z imitating chenille fleece, etc. can be formed. Among them, A-E and V-Z can be randomly combined to form various variable structures. At the same time, the respective colors of the plush systems on the front and back sides can also be independently selected and freely combined, and many style effects can also be formed from the perspective of color, without being restricted like traditional fabric structures or causing the same front and back effects and lacking creativity. Based on the fleece fabric structure, further protection is realized for the optimization of the structure and the refinement of the process, that is, the processes of the front, middle, and back combs (structural parameters such as knitting organization, yarn laying process, coil opening / closing form, warp feeding amount relationship, etc.) are defined and protected, especially the process details of the back comb are protected. Specifically, during the weaving process of the grey fabric, the process details of the back comb can be protected by adjusting the tension compensation device.

[0100] During the knitting process on the loom, the yarn shapes of the front comb, middle comb, and back comb are as Figure 5 shown. The dot matrix in the figure is used to form positioning grids for auxiliary understanding. Among them, the front comb forms a full-width 18-needle closed plain stitch, the middle comb forms a full-width 2-needle closed plain stitch, and the back comb forms a full-width 4-needle open plain stitch. Moreover, during the knitting process, the extension yarn of the back comb is woven into the grey fabric in a loose and buckled manner, forming an effect of "being stored" (similar to the state of a compressed spring).

[0101] In one embodiment, in step S200, before knitting on the loom, the tension compensation device of the back comb is adjusted, that is, the tension rod of the tension compensation device of the back comb is extended forward by 15-35 cm; and a tension spring with a tension sensitivity of not less than 0.1 cN is used for the tension compensation device of the back comb.

[0102] The working principle and beneficial effects of the above technical solution are as follows: During the weaving process of the grey fabric, adjust the tension compensation device, extend the tension rod 15 - 35 cm towards the front of the machine. At the same time, replace the tension spring with a high-precision and sensitive one (sensitive to small tension fluctuations, with a tension sensitivity not less than 0.1 cN) to be able to timely compensate for the tension adjustment in the "over-relaxed" state, thereby stabilizing and uniformizing the yarn tension and preventing the yarn of the back comb from "floating" out of control. For the excessive let-off amount of the back comb, during the knitting process, the extension yarn is loosely and bucklingly woven into the grey fabric and "stored" (similar to the state of a compressed spring). When undergoing post-processing, after the loosely buckling extension yarn is subjected to the pulling force, a part of the extension yarn (the excessive let-off amount of 50 - 200%) is transformed into loops and stretched, similar to the spring becoming straight and "pushing out" the loops. Thus, during the weaving process of the grey fabric, by adjusting the tension compensation device, the protection of the technological details of the back comb is achieved; among them, the relationship between the loop height of the back comb loop (back loop) and the let-off amount is as follows:

[0103] H = [(R - R0) ÷ 480 - 1.43d] ÷ 2 × η

[0104] Among them,

[0105] H: The loop height of the back comb loop (back loop), unit: mm; A back comb loop can be approximately regarded as a semi-circular arc + 2 loop columns, and the loop column height is H. Corresponding to the conversion coefficient value, the loop height of the back comb loop (back loop) calculated by the above formula ranges from 1.6 to 2.0 mm; In fact, the back loop height data range of 1.5 - 6.0 mm meets the requirements;

[0106] R: The actual let-off amount of the back comb; unit: mm / 480 courses;

[0107] R0: The calculated let-off amount of the back comb; unit: mm / 480 courses;

[0108] d: The thickness of the knitting needle tip, unit: mm;

[0109] η: Conversion coefficient (i.e., the back comb extension yarn is transformed into back comb loops), which is set by machine adjustment within the range of 80 - 99%. Through the above relationship formula, the loop height of the back comb loop (back loop) is correlated with the let-off amount, realizing the linkage control of the two control parameters, thereby smoothly, precisely, and efficiently producing plush fabrics with good quality consistency and strong quality stability.

[0110] In one embodiment, in step S100,

[0111] The yarn raw materials can be selected as follows:

[0112] The front comb selects 75D / 72F wave flat cross-section super dull polyester FDY filament;

[0113] The middle comb selects 45D / 24F round hole cross-section semi-dull polyester FDY filament;

[0114] The back comb selects 75D / 144DF round hole cross-section full dull polyester DTY filament.

[0115] The working principle and beneficial effects of the above technical solution are:

[0116] The method of warping the yarn is as follows:

[0117] Front comb: Use an SGZ400D intelligent computer-controlled warping machine, beam specifications: Φ21×21” (inch); number of warp ends: 293; number of warping beams: 8; warping speed: 1200 rpm; warping tension: 8 - 9 cN;

[0118] Middle comb: Use an SGZ300D computer-controlled high-speed warping machine, beam specifications: Φ21×21”; number of warp ends: 588; number of warping beams: 8; warping speed: 1500 rpm; warping tension: 5 - 6 cN;

[0119] Back comb: Use an SGZ400D intelligent computer-controlled warping machine, beam specifications: Φ21×21”; number of warp ends: 588; number of warping beams: 8; warping speed: 1200 rpm; warping tension: 8 - 9 cN.

[0120] The working principle and beneficial effects of the above technical solution are: This solution further defines the adopted yarn raw materials, equipment operation parameters, and feeding parameters (warping amount). For the production of plush fabric products, it enhances the operability and guidance in the production process, is conducive to production standardization, product quality control and management, and is conducive to improving production efficiency.

[0121] In one embodiment, as Figure 4 shown, in step S300, the dyeing and finishing process includes:

[0122] Sequentially perform pre-setting on the back side of the second plush layer (referring to this side of the second plush layer, that is, the back side), back side raising or sanding, and back side shearing; Pre-setting the back side of the greige fabric is to perform pre-setting with the back side of the greige fabric facing up (temperature 180 - 190 °C, for example, using a temperature of 185 °C, vehicle speed 20 - 25 m / min), so that the greige fabric obtains stable dimensions and structural forms; Raising uses a 48-roll × 2 and 60-roll × 2 raising machine, and the four-connected rolls continuously raise the back side of the greige fabric to obtain short, dense, and uniform plush;

[0123] Perform pre - setting, napping, and calendering on the first plush layer side (referring to this side of the first plush layer, i.e., the front side) in sequence. The pre - setting of the front side of the greige fabric is to pre - set the front side of the greige fabric with the front side up (temperature 215°C, vehicle speed 20 m / min), so that the greige fabric obtains a certain stiffness. The napping on the front side uses a 24 - roller × 2 and 36 - roller × 2 napping machine, and the four - roller continuously raises the nap on the front side of the greige fabric to obtain long and uniform long hair. The calendering conditions on the front side are: temperature 170 - 180°C, vehicle speed 15 - 20 m / min;

[0124] Perform dyeing, washing, softening, drying, and hot air blowing on the first plush layer side and the second plush layer side processed previously in sequence. The greige fabric dyeing, white fabric dyeing (yarn - dyed greige fabric does not need dyeing), uses a high - temperature and high - pressure liquid - flow dyeing machine, and uses disperse dyes to dye in an environment of pH 6 - 7. The heating rate is 1.5°C / min, the holding temperature is 120 - 130°C, the holding time is 30 - 45 min, and the cooling rate is 1.8°C / min; Dyeing can achieve alkali reduction. Washing and softening: Use padding for softening. Mix softening agents and smoothing agents at a concentration of 30 - 60 g / L with tertiary water, inject them into the padding trough, and use the two - dip and two - roll method. The softening speed is controlled at 5 - 15 m / min. After softening, dehydrate the dyed fabric. Drying: Set the temperature of the stenter to 160 - 170°C, for example, 165°C, and the vehicle speed is 20 - 50 m / min, for example, 30 m / min, to remove excess moisture in the fabric. Hot air blowing: Temperature 160 - 180°C; Air volume 12 m 3 / min; Speed 20 m / min; Make the front plush more dispersed and obtain a better fluffy effect; Then, perform front - side ironing and shearing on the first plush layer side, temperature 170 - 190°C, cut off the too - long fluff, improve the flatness and hand feeling of the front side, and basically shape the front - side plush form. Perform back - side shearing on the second plush layer side. Back - side shearing: The shearing depth is 0.5 mm, the knife - lifting angle α = 12°, the circular knife speed is 900 r / min, cut off the too - long fluff to reduce the part of the long hair on the back side that is stretched under the action of water flow and cylinder wall friction after entering the cylinder; Finally, perform pilling processing and fabric rolling on the greige fabric (here referring to the greige fabric processed through the above - mentioned processes). Pilling: Set the temperature inside the pilling cylinder at 120°C, perform pilling with steam injection, make the front - side style of the fabric surface clearer and fresher, make the plush on the back side shrink, hold together, and even form pills again to prevent hair loss; Fabric rolling: The form of the fabric after pilling is finally fixed, and it is rolled and stored in the warehouse.

[0125] The working principle and beneficial effects of the above - mentioned technical solution are: For the warp - knitted fleece fabric of this solution, its fabric processing procedures are as Figure 4As shown in the figure, the following steps can be adopted: S1. Perform pre-setting with the back side facing up (referring to pre-setting the back side of the grey fabric). The purpose is to enable the grey fabric to obtain a preliminary stable size and morphological structure after passing through the heating stage, heat balance stage, fiber molecular chain rearrangement stage, and cooling stage, especially to make the fabric surface tension uniform and the back side coil size and height uniform (which is conducive to subsequent uniform back side raising or sanding); S2. Perform raising on the back side (36 - 60 roller elastic needles or straight needles can be used to ensure that the raised hairs are dense and uniform, and do not shed or damage the coil roots) or sanding (use a sandpaper sanding machine to grind and even out the front and back side coils); S3. Second pre-setting of the grey fabric (referring to pre-setting the front side of the grey fabric) (with the front side facing up, at 210 - 220 °C, 20 m / min. The temperature cannot be too high. If the setting temperature exceeds 220 °C, the feel of the fabric will become hard; if the setting temperature is lower than 210 °C, the fabric will be too soft and not stiff enough. When raising, it is easy to be affected by the bent needles, resulting in the fabric surface becoming loose, causing uneven raising and incomplete or bottomless raising, and the bottommost extension line cannot be broken); S4. Perform raising on the front side (20 - 36 roller steel needles or bent needles can be used. The front side hair height is relatively high, and it is not suitable to use a raising machine with more than 36 rollers. First, use the bent needles to hook up the extension line and then break it); S5. Perform light calendering on the front side (at 170 - 180 °C, 15 - 20 m / min), to endow the front side plush fabric with a certain luster and flatness; S6. Trim the back side (the trimming depth is 0.5 mm, and the knife-lifting angle is α. The purpose is to reduce the elongation of the long hairs on the back side under the action of water flow and cylinder wall friction after entering the cylinder) → S7. Dyeing (wash away the residual floating hairs on the back side after trimming to reduce hair shedding, and at the same time allow the fabric to fully shrink in the high-temperature dyeing cylinder, making the back side plush more dense. When the bottom yarn is sea-island silk, alkali deweighting treatment is required) → S8. Water washing and softening → S9. Drying and setting (160 - 170 °C, 30 m / min can be adopted) → S10. Hot air blowing at 160 - 180 °C, 20 m / min, to make the front side plush more dispersed and obtain a better fluffing effect → S11. Trim the back side (the trimming depth is 0.2 mm, and the knife-lifting angle is β, trim the overlong hairs) → S12. Front side trimming and calendering (trim the overlong hairs to improve the flatness and feel of the front side, and basically fix the shape of the front side plush) → S13. Shaking granulation (add 120 °C steam for shaking granulation to make the plush on the back side contract, embrace, and even granulate again to prevent hair shedding) → S14. Roll up the fabric.Among them, the processing of the back sides (S1, S2, and S6) and the front sides (S3, S4, and S5) can be independent of each other without interference. That is, the front side can be processed first, the back side can be processed first, the front and back sides can be processed simultaneously, or the different processes of the front side (S3, S4, and S5) and the different processes of the back side (S1, S2, and S6) can be interspersed (for example, in the order of S3, S1, S4, S2, S5, and S6); that is to say, there will be no mutual restriction between the processes of the front side (S3, S4, and S5) and the back side (S1, S2, and S6). The two sides of this warp-knitted fleece can be processed independently. One side can be raised or napped, and the other side can be raised. The processing of the two sides does not affect each other and can be carried out independently. According to the specific product style, the above processing procedures can be partially increased or decreased and the order can be adjusted. Then, the front and back sides are processed together in S7, S8, S9, and S10; then, S11 on the back side and S12 on the front side are carried out. S11 on the back side and S12 on the front side can be carried out simultaneously, or S11 on the back side can be carried out first and then S12 on the front side, or S12 on the front side can be carried out first and then S11 on the back side; finally, S13 and S14 are carried out; using the above process, the final fabric is obtained, and its finished weight is: 420 g / m². 2 , the pile height on the front side is 8.5 mm, presenting the appearance effect of imitation rabbit hair, and the back side is fine and short plush, presenting the appearance effect similar to suede. Moreover, not only the plush appearance styles of the front and back sides are very different, but also the colors are different, forming the "fleece" effect like the combination of two fabrics. This fleece fabric is tested according to the AATCC-2019 standard: the hair loss rate is 0.071%, and the horizontal washing shrinkage rate is 0.1%, that is, the hair loss rate and the horizontal washing shrinkage rate are low; the longitudinal tearing strength is 35.7 N, and the air permeability is 1690 g / m² 2 / 24 hrs, that is, the longitudinal tearing strength and the air permeability are good.

[0126] During the dyeing and finishing process, as Figure 6 shown, the dot matrix in the figure is used to form a positioning grid for auxiliary understanding. The extension line of the front comb is broken to form the first plush layer; the coils and extension lines of the middle comb basically do not change much and constitute one part of the connection layer; after the loose and buckled extension lines of the back comb are affected by the raising external force, a part of the extension lines are transformed into coils and are stretched, similar to the spring becoming straight, and through raising or napping, the second plush layer is formed.

[0127] In one embodiment, in step S200, during the knitting process, for the knitting yarn, a CCD camera is used to take an image of the yarn feeding and detect the vibration of the knitting machine;

[0128] Each single yarn is identified through image recognition. According to the feeding distance of each single yarn and the detected vibration data of the knitting machine, simulation technology is used to conduct a vibration transfer simulation analysis on the single yarn, and the vibration data of each point of the single yarn within the feeding distance is obtained; the vibration data includes the vibration amplitude.

[0129] Machine vision recognition technology is adopted to perform image preprocessing on the captured real-time image, distinguish each single yarn through image recognition, and combine the vibration data of the corresponding single yarn to implement image analysis of each single yarn, so as to obtain the wire diameter data of each point of the single yarn being fed in real time.

[0130] The wire diameter data is compared with the upper limit threshold and the lower limit threshold of the wire diameter of the corresponding single yarn. If the wire diameter data deviates from the wire diameter range defined by both the upper limit threshold and the lower limit threshold of the wire diameter, a warning message is issued.

[0131] The working principle and beneficial effects of the above technical solution are as follows: This solution takes into account that the yarn raw material in the form of a roll (bundle) is not suitable for carrying out wire diameter detection one by one before use. In order to prevent the wire diameter deviation of the yarn in the middle of the roll (bundle) from exceeding the standard, resulting in uneven appearance and quality of the knitted velvet fabric; this solution adopts machine vision recognition technology to monitor the wire diameter of the feeding yarn in real time, and introduces simulation technology to conduct vibration transfer simulation analysis, taking the vibration data obtained from the analysis into consideration during wire diameter monitoring, so as to achieve the purpose of vibration compensation for wire diameter monitoring, making the wire diameter data obtained from wire diameter monitoring more accurate and reliable, reducing the wire diameter monitoring error; then, through the allowable wire diameter range determined by the preset upper limit threshold and lower limit threshold of the wire diameter, it is judged whether the real-time wire diameter data meets the requirements; for example: if the maximum size of the outer edge of the movement range of a certain point of the yarn obtained from the image analysis of each single yarn under the influence of vibration is 45 mm, and the vibration amplitude of this point obtained from the vibration transfer simulation analysis in the simulation is 21.5 mm (which means that the center of the yarn at this point will generate a radial deviation movement of 21.5 mm in any radial direction of 360 degrees), then the wire diameter data of this point monitored in real time can be obtained as 2 mm (that is, 45 mm - 21.5 mm × 2 = 2 mm); this solution issues a warning message when the wire diameter data deviates, so that the staff can take corresponding measures in time, which can improve the quality consistency, stability and yield rate of the product, reduce defective products and substandard products, and thus improve the efficiency.

[0132] In addition, multiple second CCD cameras can be set up to respectively capture the knitting images of the yarns on the front comb, middle comb, and back comb from multiple angles, such as shooting at set angles from the side, top, bottom, etc. of the machine, and performing image preprocessing on the knitting images of the yarns on each comb; then, determining the crossing rules of the yarns on each comb, as well as the upper and lower hierarchical positions and structural relationships formed by the knitting of the yarns on each comb through image recognition. For example, when shooting from the side of the machine, from top to bottom, the structural levels of the fabric formed by the correct knitting method can be: the front comb extended yarn layer, the middle comb extended yarn layer, the back comb extended yarn layer, the middle comb coil layer, the front comb coil layer, and the back comb coil layer; comparing the crossing rules of the yarns, the upper and lower hierarchical positions and structural relationships formed by the knitting of the yarns with the corresponding set standards respectively to determine whether they meet the requirements. For example, if the crossing rules are the same as the set crossing rule standards, it means they meet the requirements; if they do not meet the requirements, corresponding measures are taken for adjustment. In this way, the quality consistency, stability, and yield rate of the product can be further improved, the number of unqualified and defective products can be reduced, and thus the efficiency can be increased.

[0133] In one embodiment, by recording and storing the wire diameter data of each point of a single yarn, the following formula is used to calculate the uniformity index of the single yarn:

[0134]

[0135] In the above formula, τ represents the uniformity index of a single yarn; n represents the total number of monitoring points of the wire diameter data of a single yarn (i.e., also the total number of wire diameter data); d i represents the wire diameter data of the i-th point of the monitored single yarn; represents the average value of the wire diameter data of the monitored single yarn;

[0136] According to the usage of each single yarn in the yarn raw material during knitting (such as which part of the plush fabric of the knitted product it is used for, etc.), weight assignments are given to each single yarn;

[0137] Combining the uniformity index and weight assignment of each single yarn, the quality data of the knitted plush fabric is evaluated. For example, the quality data of the plush fabric can be equal to the sum of the products of the uniformity index of each single yarn and its corresponding weight assignment; the quality grading and management of the plush fabric are carried out according to the quality data.

[0138] The working principle and beneficial effects of the above technical solution are as follows: Based on the above-mentioned wire diameter data monitoring, this solution uses a set algorithm to evaluate the uniformity of the wire diameter of the yarn, so as to obtain the quality evaluation of the yarn raw material. This quality evaluation of the yarn raw material can be used as the basis for future selection of yarn raw materials; further combined with the weight borne during its weaving, the quality data of the woven plush fabric is analyzed, and based on this, the quality grading and management of the plush fabric are carried out; using this solution avoids the influence of human subjective factors in quality evaluation and improves the objectivity and reliability of quality evaluation.

[0139] The present invention can achieve the following beneficial effects:

[0140] 1. The present invention uses a warp-knitted integral fleece to replace the weft-knitted integral fleece, which solves the problems of the loose structure, insufficient density, easy shedding of weft-knitted coils, and low connection strength between the two sides of the weft knitting relying on a single yarn. At the same time, it also overcomes the inherent structural limitations of the weft-knitted integral fleece fabric with a plain cloth on one side and plush on the other side, as well as the shedding problem caused by the simple pressing of the wool yarn by the backing yarn (or called "binding wire") in the weft-knitted plush. In addition, compared with the weft-knitted integral fleece, the warp-knitted integral fleece has a higher knitting production efficiency, and it is easier to realize the production of wide-width and extra-wide-width fabrics. Moreover, this warp-knitted integral fleece structure can be realized on an ordinary single-needle bed warp knitting machine (single-sided warp knitting machine), without relying on double-sided machines or special weft knitting equipment, and the production using a single-sided warp knitting machine is simple and efficient.

[0141] 2. By adopting an innovative warp-knitting structure, the limitation of the inherent structure of the warp-knitted plush fabric is broken through, and the problem that the plush on the front side and the base cloth on the back side of the fabric are made of the same yarn raw material, and the back side cannot be directly used and needs to be compounded or raised is solved. For compounding, it increases the production process and loss, and there are problems such as chemical residue hazards and poor durability when using glue for compounding; for raising the warp-knitted plush, about 40% of the plush on the front side is pulled to the back side. Essentially, the material, hair height, and style of the plush on the back side can only depend on the plush on the front side. The plush on the front and back sides affect each other, and the two cannot be formed and processed independently, resulting in a single and similar pile feeling on the front and back sides of the fabric, lacking creativity, and reducing the fullness of the plush on the front side. Moreover, during the process of pulling the plush from the front side to the back side, passing through the base cloth will cause damage to the fabric structure and fibers, and further exacerbate shedding. The warp-knitted plush of the present invention, through structural innovation, does not require compounding, nor does it require pulling the plush on the front side through the base cloth to the back side. Instead, the front and back plush are regarded as two independent systems, without affecting each other, so as to effectively solve many drawbacks of compounding and pulling the front plush to the back side from the physical structure aspect.

[0142] 3. The warp-knitted single-sided fleece of the present invention has a relatively high degree of freedom in the dyeing and finishing process. The plush on the front and back can be processed independently of each other without mutual influence. According to the final required product style, the plush on the back can be processed first, and then the plush on the front can be processed, or the processing order of the front and back can be exchanged. In contrast, the processing process of traditional warp-knitted plush fabrics is relatively fixed. Generally, only the plush on the front can be processed first. After the style of the plush on the front is basically formed, the plush part on the front is pulled to the back to form double-sided plush. The processing of weft-knitted single-sided fleece usually also focuses on the plush on the front, with less processing involved in the back part. However, the processing of the warp-knitted single-sided fleece of the present invention breaks the limitations of the processing of traditional warp-knitted or weft-knitted plush fabrics. It has strong priority selectivity and flexibility in the processing of both sides, and different post-treatment processes can also be used for both sides, without being restricted to a single processing method. Moreover, it effectively avoids the many problems caused by the mutual influence and restriction of the plush on the front and back during the processing of traditional double-sided plush fabrics. The dyeing and finishing process of the warp-knitted single-sided fleece improves the post-treatment process of weft-knitted single-sided fleece and conventional warp-knitted double-sided fleece, making its operation more flexible and variable. At the same time, it also avoids the problems that occur in the traditional dyeing and finishing process and improves the quality of the product.

[0143] 4. Due to the mutual independence of both sides of the warp-knitted single-sided fleece, it has multiple independences in terms of the selection of yarn raw materials, color selection, yarn threading rules, appearance form, etc. on both sides, and there are multiple combinabilities between the two sides, thus greatly enhancing the richness of the warp-knitted single-sided fleece products. In addition, during the fabric processing and later use process, problems such as fabric damage and breakage caused by loose structure and loop shedding are not likely to occur. Moreover, the lateral and longitudinal dimensional stability of this fabric is extremely excellent. Under multiple washing conditions, its lateral shrinkage rate can be maintained at 0-0.2%, which has a significant advantage compared with the lateral shrinkage rate of 1-3% of traditional process products. Another test according to the AATCC-2019 standard shows that the hair loss rate of this warp-knitted single-sided fleece fabric is 0.01-0.1%, less than 0.1%; the longitudinal tear strength is 25-50N, and the air permeability is 1500-2000g / m 2 / 24hrs, that is, the air permeability is greater than 1500g / m 2 / 24hrs, thereby improving the daily use performance and comfort of the product.

[0144] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to include these modifications and variations.

Claims

1. A warp knitted one-piece velvet fabric, characterized in that: It comprises a first plush layer, a second plush layer and a connecting layer located between the first plush layer and the second plush layer; The first plush layer includes a front comb extension line layer, which is formed by processing the front comb extension line; The connecting layer includes a middle comb extension line layer, a back comb extension line layer, a middle comb coil layer and a front comb coil layer in sequence from the first plush layer to the second plush layer, and each layer is formed by interlacing the middle comb extension line, the back comb extension line, the middle comb coil and the front comb coil in sequence; The second plush layer includes a back-combed coil layer, a back-combed extension line layer or a combination of the two, wherein the back-combed coil layer is formed by processing the back-combed coil, the back-combed extension line layer is formed by processing the back-combed extension line, and the combination layer is formed by processing the back-combed coil and the extension line; The front comb adopts N+1 needle closed warp plain weave, and the inlay yarn is digitally recorded as: 1-0 / N-(N+1) / / (N≥15); or, The front comb uses two N+1 needles and P+1 needles in the same direction for closed warp plain weave, and the inlay yarn numbers are recorded as: 1-0 / N-(N+1) / / (N≥15) and 1-0 / P-(P+1) / / (P≤10); The middle comb adopts L+1 needle closed warp plain weave, and the lapping yarn is digitally recorded as: L-(L+1) / 1-0 / / (1≤L≤3); or, The middle comb adopts two reverse L+1 needles closed warp plain weave, and the lapping yarn numbers are recorded as: L-(L+1) / 1-0 / / (1≤L≤3) and 1-0 / L-(L+1) / / (1≤L≤3); The back comb adopts M+1 needle open warp plain weave, and the inlay yarn is digitally recorded as: 0-1 / (M+1)-M / / (2≤M≤5); or, The back combing adopts M needle weft insertion structure, and the inlay yarn is digitally recorded as: MM / 0-0 / / (2≤M≤5); or, The back comb adopts M+1 needle open warp plain weave, and the inlay yarn is digitally recorded as: (M+1)-M / 0-1 / / (2≤M≤5); or, The back combing adopts two reverse M+1 needles open warp plain weaves, and the inlay yarn numbers are recorded as: 0-1 / (M+1)-M / / (2≤M≤5) and (M+1)-M / 0-1 / / (2≤M≤5), or, the back combing adopts two reverse M needles weft insertion weaves, and the inlay yarn numbers are recorded as: 0-0 / MM / / (2≤M≤5) and MM / 0-0 / / (2≤M≤5); or, the back combing adopts one M+1 needle open warp plain weave and one M needle weft insertion weave, and the inlay yarn numbers are recorded as: 0-1 / (M+1)-M / / and 0-0 / MM / / (2≤M≤5).

2. The warp-knitted one-piece fleece fabric according to claim 1, characterized in that: The front comb uses 75-300D polyester DTY round-hole low-elastic yarn with a single-filament fineness range of 0.52-1.04D, or 75-300D polyester FDY flat-section filament with a single-filament fineness range of 1.04-4.16D; The middle comb uses 50-100D polyester FDY or DTY ordinary polyester filament; For the back combing, 75-300D polyester DTY round-hole low-elastic yarn is used, and the single-filament fineness ranges from 0.52 to 1.04D; or one of 75-300D polyester sea-island yarn, solution-dyed polyester filament, lyocell filament and mulberry silk is used.

3. The method for preparing the warp-knitted integrated fleece fabric according to any one of claims 1-2, characterized in that: The following steps are involved: S100: determining the yarn raw material for weaving, and using the selected warping machine to warp the yarn; S200: A warp knitting machine with no less than three combs is used. The combs are divided into three groups for weaving the front, middle and back combs respectively. A. Wearing the warp: front comb: 1 through and 1 empty; middle comb: full through; back comb: full through; B. Weaving: Weaving process is carried out according to the following warp let-off: Front combing: the actual let-off amount used is 0.9 to 1.1 times the calculated let-off amount; Middle combing: the actual let-off amount used is 0.85 to 0.95 times the calculated let-off amount; Back combing: The actual let-off amount used is 1.5 to 3 times the calculated let-off amount; The drawing density used in weaving is in the range of 13-20 cpc, and the starting speed is in the range of 1500-2200 rpm; S300: dyeing and finishing the woven grey cloth to obtain a warp knitted integrated velvet fabric.

4. The method for preparing the warp-knitted integrated fleece fabric according to claim 3, characterized in that: In step S200, before weaving on the machine, the back comb tension compensation device is adjusted, that is, the tension rod of the back comb tension compensation device is extended forward by 15 to 35 cm; and the back comb tension compensation device adopts a tension spring with a tension sensitivity of not less than 0.1 cN.

5. The method for preparing the warp-knitted integrated fleece fabric according to claim 3, characterized in that: In step S100, the yarn warping method is as follows: Front combing: SGZ400D intelligent computer-controlled warping machine, warping head specification: Φ21×21”; number of warping head grains: 293; number of warping heads: 8; warping speed: 1200rpm; warping tension: 8~9cN; Middle carding: SGZ300D computer-controlled high-speed warping machine is used, warping head specification: Φ21×21”; number of warping head grains: 588; number of warping heads: 8; warping speed: 1500rpm; warping tension: 5~6cN; Post-combing: SGZ400D intelligent computer-controlled warping machine is adopted, warping head specification: Φ21×21”; number of warping head grains: 588; number of warping heads: 8; warping speed: 1200rpm; warping tension: 8~9cN.

6. The method for preparing the warp-knitted integrated fleece fabric according to claim 3, characterized in that: In step S300, the dyeing and finishing process includes: The second plush layer side is sequentially subjected to back pre-shaping of the grey fabric, back napping or back napping, and back nap shearing; The first plush layer side is sequentially subjected to front pre-forming, front napping and front ironing processing of the grey fabric; The first plush layer side and the second plush layer side after the previous processing are dyed, washed, softened, dried and hot-blown in turn; then the first plush layer side is ironed and sheared on the front side, and the second plush layer side is sheared on the back side; finally, the grey cloth is subjected to polarizing and fabric curling.

7. The method for preparing the warp-knitted integrated fleece fabric according to claim 3, characterized in that: During the weaving process, a CCD camera is used to capture images of the yarn feeding and to detect the vibration of the weaving machine. Through image recognition, each single yarn is distinguished, and according to the feeding distance of each single yarn and the detected vibration data of the knitting machine, the vibration transmission simulation analysis of the single yarn is carried out by using simulation technology to obtain the vibration data of each point of each single yarn within the feeding distance; the vibration data includes the vibration amplitude; The machine vision recognition technology is used to pre-process the real-time images taken, and the individual yarns are distinguished through image recognition. Combined with the vibration data of the corresponding individual yarns, the image analysis of each individual yarn is carried out to obtain the wire diameter data of each point of the single yarn fed in real time; The wire diameter data is compared with the wire diameter upper limit threshold and the wire diameter lower limit threshold of the corresponding single yarn. If the wire diameter data deviates from the wire diameter range defined by both the wire diameter upper limit threshold and the wire diameter lower limit threshold, a warning message is issued.

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