Warp-knitted double-cut loop pile fabric and method of knitting the same

Abstract

The invention discloses a weft-knitted compound cut-loop pile fabric, which is knitted by ground yarns and pile yarns. The ground yarns form the ground stitch in the stitch structure of the weft-knitted compound cut-loop pile fabric, and each ground yarn forms a horizontal ground stitch. The pile yarns form the cut-loop pile in the stitch structure of the weft-knitted compound cut-loop pile fabric. The pile yarns are knitted in a multi-pile / single-pile fixed loop in a multi / compound sub-step mode according to respective rules in one horizontal ground stitch. The fixed loop is a loop knitted by the pile yarn and the ground yarn. The loop arc of each pile yarn between the multi-pile / single-pile fixed loops is cut according to requirements. The loop arc includes a float or a sinker arc. The knitting courses between the horizontal cut-loop pile courses can be designed as common knitting courses. The weft-knitted compound cut-loop pile fabric includes plain pile fabric, jacquard pile fabric and high-low pile fabric. The invention relates to the technical field of knitting, and specifically provides a weft-knitted compound cut-loop pile fabric and a knitting method thereof.

Description

Technical Field

[0001] This invention relates to the field of knitting technology, specifically to weft-knitted compound cut loop pile fabric and its knitting method. Background Technology

[0002] Weft-knitted cut-loop pile fabric is woven using a double-needle bed circular knitting machine. The double-needle bed machine's needle bed (or cylinder) is equipped with needles that knit the ground yarn and pile yarn into a plain knit base structure. The needle bed (or cylinder) is equipped with cutting needles (or integrated needles) that only hook the pile yarn to form elongated loops. The cutting needle's blade cuts the loops to form pile, which adheres to the base structure, thus knitting the cut-loop pile fabric. In existing cut-loop pile fabrics, the pile yarn is fed into only one location within a loop-forming system and is regularly spaced on the needles to form loops. The number of consecutive loop stitches and the number of interval stitches are generally the same, mostly 1-3 stitches. The number of consecutive loop stitches reflects the strength of the pile yarn's bond in the fabric; the more consecutive loop stitches, the better the bond. However, the more consecutive knit stitches, the fewer elongated loops the pile yarn forms, resulting in a sparser pile. Generally, cut loop pile fabrics also have plain knitted structure rows between the cut loop pile rows to adjust the fabric's density, weight, loop strength, and unraveling properties.

[0003] Besides producing cut loop pile fabrics, weft-knitted cut loop pile fabrics can also use a needle selection mechanism to select the needles and control their working state, thereby producing jacquard cut loop pile. By using needle triangles with different pressure depths, it is also possible to produce cut loop pile with varying pile heights.

[0004] After improvements to the double-needle bed cut loop pile machine, it is possible to weave a cut loop pile fabric with a relatively fine plain weave on one side and a composite structure of cut loop pile and looped loops on the other side. The fine side covers the rough reverse side of the cut loop pile, improving its wearing performance.

[0005] Due to its various excellent properties and appearance, cut loop pile fabrics are widely used in clothing, toys, carpets, car decorations and home textiles, and the demand is large.

[0006] However, current cut loop pile fabrics use only one pile yarn fed per weaving row. To obtain high-density, full-needle cut loop pile, a single-needle knotting method is used. However, single-needle knotting is prone to pile shedding and is rarely used for apparel fabrics. When using this structure for carpets, adhesive backing is used for reinforcement, increasing production steps and costs, and also having an adverse impact on the environment. When using multi-needle knotting to produce cut loop fabrics, pile shedding can be reduced, but the pile density will decrease, becoming sparser, making it difficult to produce high-end pile products. When making multi-color jacquard pile fabrics, if the pile knotting strength is to be considered, the pile density is even lower and sparser, leading to the appearance of the underlying material, which greatly reduces the product's usability and makes it difficult for the market to accept.

[0007] To further improve the performance, quality, and diversity of cut loop pile products and achieve product upgrades, it is urgent and important to solve the technical problems of cutting loop pile fabrics and weaving methods that ensure both strong bonding and sufficient pile density. Summary of the Invention

[0008] In view of the above situation and to overcome the existing defects, the present invention provides a weft-knitted compound cut loop pile fabric and its knitting method.

[0009] The present invention provides the following technical solution: The weft-knitted double-cut loop pile fabric proposed in the present invention is woven from ground yarn and pile yarn. The ground yarn forms a base structure in the yarn-adding loop structure of the weft-knitted double-cut loop pile fabric, and each ground yarn forms a horizontal base structure. The pile yarn forms cut loop pile in the yarn-adding loop structure of the weft-knitted double-cut loop pile fabric. The pile yarn is woven in a horizontal base structure in a multi-thread / double-layer manner according to its own rules, with multiple needles / single needle fixed loops. The fixed loops are yarn-adding loops woven together with the pile yarn. The loops between the multi-needle / single needle fixed loops of each pile yarn are cut as needed. The loops include floats or sinkers. The horizontal rows of cut loop pile can be designed with ordinary knitted structure knitting rows. The weft-knitted double-cut loop pile fabric includes solid color pile fabric, jacquard pile fabric and high-low pile fabric.

[0010] Furthermore, the weft-knitted compound cut loop pile fabric is knitted using a double-needle bed circular knitting machine. One needle bed of the loom is equipped with multi-needle knitting needles, a cam system that can feed pile yarn repeatedly, and a yarn guide. The other needle bed is equipped with cutting needles, a dedicated cam knitting system, and other auxiliary devices. When knitting jacquard pile fabric, a jacquard device that selects the cutting needles is also required.

[0011] Furthermore, the cutting needle can be a regular cutting needle or a combination cutting needle.

[0012] For ease of explanation, when describing the knitting method, it is assumed that the upper needle plate of the double-needle bed circular knitting machine is equipped with circular knitting needles, and the lower needle cylinder is equipped with cutting needles. Each machine is also equipped with a cam system, yarn guide system, and needle selection system. The ordinary fabric structure between rows of cut-loop knitting is not described in detail.

[0013] The present invention also proposes a weft-knitted double-cut loop pile fabric weaving method, specifically including the back-position double synchronous loop knitting method, the front-position double synchronous knitting method, the double step-cut loop pile knitting method, the jacquard double-cut loop pile knitting method, and the high-low double-cut loop pile knitting method.

[0014] Furthermore, the aforementioned post-positioned, double-layered, synchronous loop-forming knitting method specifically refers to:

[0015] (1) After all the knitting needles have come off the loop, the ground yarn guide feeds in the ground yarn. After the pressure triangle is activated, the ground yarn is inserted into the knitting needle. The knitting needle is pressed to the loop position, and the needle hook holds the ground yarn.

[0016] (2) Some knitting needles are pushed to the tucked position under the action of the cam, while other knitting needles still hold the ground yarn. The ground yarn is still in a straight state. The ground yarn opens the needle tongue of the knitting needle that has been pushed to the tucked position. At the same time, some of the cutter needles that are matched with this part of the knitting needles are also raised to a high position. The plush yarn guide feeds yarn to this part of the knitting needles and cutter needles. The knitting needles and cutter needles are pressed by their respective cams. The plush yarn is inserted into the hook of the knitting needle and cutter needle. The cam works further to make the knitting needle hold the plush yarn back to the loop position, level with the other knitting needles. When the cutter needles and knitting needles are arranged alternately, the cutter needle holds the yarn at the needle plane of the knitting needle at the height of the needle back, so that the yarn can be stably held by the knitting needle under low tension and the knitting needle and cutter needle do not collide. This completes the padding of one piece of plush yarn; repeat this process for the other part of the knitting needle and cutter needle combination to complete the feeding and padding of multiple pieces of plush yarn. At this time, the yarn guide, knitting needle hook and cutter needle hook form a yarn guide channel for knitting a horizontal row of plush yarn.

[0017] (3) After the ground yarn and plush yarn are placed on the knitting needle and the cutting needle, the yarn is bent into a loop on the knitting needle by the pressure needle triangle to form a flat needle yarn filling loop. At the same time, all the cutting needles will form the plush yarn into an elongated loop under the action of the triangle.

[0018] (4) All the knitting needles work again to complete the knitting of a plain fabric row, and the knife needles do not participate in the work;

[0019] (5) Press down the elongated loop of fluffy yarn formed on the cutting needle with the pressing disc. The cutting needle, driven by the action of the lifting triangular needle, cuts the loop with its blade to form fluff. If a combination cutting needle is used, the pressing disc is not needed, and the cutting edge of the cutting needle is used directly to cut the loop.

[0020] This method, in which the ground yarn is first fed into the knitting system, followed by the pile yarn, and after the padding is completed, the knitting needles and cutting needles simultaneously press and bend the yarn to form loops and arcs, ultimately forming a cut-loop pile fabric, is called the post-positioned double synchronous cut-loop pile knitting method.

[0021] Furthermore, the aforementioned pre-positioned double synchronous knitting method specifically refers to:

[0022] (1) A portion of the knitting needles and corresponding cutting needles are lifted by their respective cams. The knitting needles are lifted to the loop-off position, and the cutting needles are lifted to the position where yarn can be padded. The yarn guide feeds the pile yarn into the knitting needles and cutting needles simultaneously. Then, the pressing cam presses the knitting needles to the loop position, and the cutting needle tip is pressed to the height of the back of the knitting needle (when the cutting needles are arranged at intervals, the cutting needle hook and the knitting needle hook can be aligned), thus completing the padding of the pile yarn onto the knitting needles and cutting needles. The other portion of the knitting needles and corresponding cutting needles repeat this process of padding the pile yarn, that is, the padding of multiple pile yarns onto different knitting needles and cutting needles is completed. After the padding is completed, the yarn guide, the knitting needle hook, and the cutting needle hook form a pile yarn guiding channel;

[0023] (2) The needles are pushed to the tucked position by the action of the needle-lifting triangle. The yarn guide feeds the ground yarn into the needles. Then the needles and the cutter needles are pressed by the action of the needle-pressing triangle. The needles complete the ground yarn padding and bend the yarn into a loop together with their respective pile yarns to form a flat needle yarn-adding structure. The cutter needles simultaneously form an elongated loop arc with the pile yarn.

[0024] (3) All the knitting needles work again to complete the knitting of a plain fabric row, and the knife needles do not participate in the work;

[0025] (4) Press down the elongated loop of fluffy yarn formed on the cutting needle with the pressing disc. The cutting needle, driven by the action of the lifting triangle, cuts the loop with its blade to form fluff. If a combination cutting needle is used, the pressing disc is not needed, and the cutting edge of the cutting needle is used directly to cut the loop.

[0026] This method, in which multiple strands of plush yarn are first fed into the knitting system, followed by the ground yarn, and the knitting needles and cutting needles press simultaneously to form loops and arcs, and finally the loops are cut to form a cut loop plush fabric, is called: pre-positioned double synchronous cut loop plush knitting method.

[0027] Furthermore, the aforementioned compound step-by-step loop-cutting knitting method specifically refers to the following: based on the above-mentioned post-compound synchronous loop-forming knitting method and pre-compound synchronous knitting method, after each feeding of pile yarn is placed on the cutting needle, the cutting needle continues to be pressed to the final required depth by the action of the pressure needle triangle, forming an elongated pile yarn loop arc. That is, the loop arc formation of each pile yarn is carried out separately. When using this step-by-step knitting loop arc method, when the knitting needle enters the loop-forming stage, the cutting needle needs to retract to a certain extent to provide the knitting needle with the required yarn for the pile yarn to form a loop, reduce knitting tension, and avoid yarn breakage.

[0028] This method of directly weaving plush yarn into loops in steps is called: compound step-by-step loop weaving method.

[0029] Furthermore, the specific knitting method of the jacquard double-cut loop pile refers to the following: based on the rear double synchronous loop knitting method, the front double synchronous knitting method, and the double step-cut loop pile knitting method, different colored yarns are used for the pile yarns fed in a horizontal row, and the cutting needles in a cycle correspond to different colored yarns. To obtain a single-color block in the jacquard cut loop pile, only the cutting needles corresponding to one color yarn in a cycle should work to form pile. The pile yarns that do not form pile are not cut by the cutting needles at the position of the cutting needles, but only form floating threads. These floating threads are covered by the formed colored pile and are inside the colored pile. This allows for the selection of single-color display areas. This necessitates selective needle selection from a cyclically arranged array of needles. A weft needle selection mechanism is used during knitting; a mechanical needle selection mechanism is used for small patterns, while an electronic needle selection mechanism is used for large patterns. The needle selection mechanism employs a two-station design. When knitting using this mechanism, the needles use a single-needle heel needle. The needle pressing action is generated by the action of the needle pressing triangle against the needle heel. The needle lifting action is completed by the needle selection mechanism. This allows for the specification of color for each display unit as needed, which can be either single-color or mixed-color, thus obtaining various patterns of multi-color jacquard loop pile.

[0030] This knitting method, which uses a needle selection mechanism to select needles for the cutting needles, to create a double plain jacquard cut loop pile, is called: jacquard double cut loop pile knitting method.

[0031] Furthermore, the knitting method of high and low pile double-cut loop pile specifically refers to: multiple pile fabrics of different pile heights forming a certain pattern, with some areas of the pattern being high pile and others being low pile or even no pile, thus forming a pattern with a three-dimensional effect of concave and convex textures. To obtain high and low pile double-cut loop pile, the feeding system of the pile yarn must also be equipped with a needle selection device with at least two positions, that is, the loom must have the function of a jacquard pile double-cut loop pile machine, and at the same time be equipped with a knife needle and knife needle triangle system that can knit high and low pile heights. Therefore, the knitting of high and low pile double-cut loop pile can be achieved by constructing the knife needle path of high and low pile heights on the basis of jacquard double-cut loop pile.

[0032] In a step-by-step loop knitting system, the longest possible pile length for jacquard cut loop pile is set as the maximum pile height, and the pile lengths of other yarns decrease sequentially, thus creating cut loop piles with different pile heights. During knitting, the first yarn fed into a row is pressed to its deepest point by the pressure triangle of the selected needle, forming the longest pile loop. Subsequent yarns are fed with progressively lower pressure depths, and so on, resulting in different pile heights. After cutting the loops, high and low cut loop piles are formed.

[0033] In a synchronous loop knitting system, the needle feet are designed with different heights, and the needle presser triangles are designed with different thicknesses to correspond to them. At the same time, the presser depth of the presser triangles of different thicknesses is designed to the required value. The longer the needle foot, the deeper the presser depth, the longer the loop arc formed, and the higher the pile formed after the loop is cut. This can also form high and low loop pile.

[0034] When the needle selection mechanism adopts a three-station design, the needle triangle system can be adjusted appropriately to obtain solid color high and low cut loop pile with full needle pile or all needles working.

[0035] This method of creating high-low lobed pile by simultaneously configuring high-low lobed pile triangles on the basis of jacquard lobing is called: high-low double lobed pile weaving method.

[0036] Furthermore, based on this scheme, in the production of cut loop pile, replacing all the cutting needles with hook needles without latches can produce weft-knitted terry fabrics; replacing some of the cutting needles with hook needles without latches can produce double-effect fabrics that interweave terry and cut loop pile, all of which are within the protection scope of this scheme.

[0037] The beneficial effects achieved by the present invention using the above structure are as follows: The weft-knitted compound cut-loop pile fabric and its knitting method proposed in this invention, in the same knitting row, feeds multiple pile yarns into the knitting system and forms pile in different parts, so that pile yarn loops (fixed loops) can be formed on all the knitting needles of the base fabric. The main advantages of this technology are:

[0038] (1) Based on reliable plush fastness, the density of plush has been greatly improved, so that more refined raw materials can be used to produce high-end fine plush products, realize the upgrading of cut loop plush products, and meet the requirements of the high-end market.

[0039] (2) The use of double-cut loop pile production technology can make multi-color (multi-high pile) jacquard cut loop pile fabrics into practical products. The double production method avoids the exposed base of the fabric, resulting in high pattern clarity, strong sense of layering, and full hand feel, which can satisfy people's beautiful aspirations for multi-color cut loop pile jacquard fabrics;

[0040] (3) In the double-cut loop pile, one ground yarn simultaneously binds multiple pile yarns, resulting in high binding efficiency and a small proportion of ground yarn used, which can relatively reduce raw material costs.

[0041] (4) The multiple cut loop pile yarns of the double loop pile are woven in one horizontal row, which reduces the number of knitting systems in the plain needle structure and increases the number of cut loop pile knitting systems installed on the loom, which can significantly improve the production efficiency of the loom. Attached Figure Description

[0042] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0043] Figure 1 This is a schematic diagram of the structure of the two-needle fixed two-thread double-cut loop pile fabric and the weaving method of the present invention.

[0044] Figure 2 This is a schematic diagram of the movement trajectory of the knitting machine parts in the post-rear double-cut loop pile synchronous knitting method of the weft knitted double-cut loop pile fabric and weaving method of the present invention.

[0045] Figure 3 This is a schematic diagram of the movement trajectory of the knitting machine parts in the pre-process double-cut loop pile knitting method of the weft-knitted double-cut loop pile fabric and weaving method of the present invention.

[0046] Figure 4 This is a schematic diagram of the movement trajectory of the knitting machine parts in the post-rear double-cut loop pile knitting method of the weft-knitted double-cut loop pile fabric and weaving method of the present invention.

[0047] Figure 5 This is a schematic diagram of the movement trajectory of the knitting machine parts in the pre-duplicate cut loop pile synchronous knitting method of the weft knitted double cut loop pile fabric and weaving method of the present invention.

[0048] Figure 6 This is a schematic diagram of the movement trajectory of the knitting machine parts in the pre-process double-layer high and low cut loop pile knitting method of the weft knitting double-layer cut loop pile fabric and weaving method of the present invention.

[0049] Figure 7 This is a schematic diagram of the movement trajectory of the knitting machine parts in the post-positioned double-layer high and low-layer cut loop synchronous knitting method of the weft-knitted double-layer cut loop fabric and weaving method of the present invention.

[0050] Figure 8 This is a diagram of the two-needle fixed two-color jacquard double-cut loop pile knitting method of the present invention.

[0051] Figure 9 This is a diagram of the two-needle fixed three-color jacquard double-cut loop pile knitting method of the present invention.

[0052] Figure 10 This is a diagram of a two-needle double-pile yarn bonded three-color jacquard double-pile knitting fabric and weaving method of the present invention.

[0053] Figure 11 This is a diagram of a two-needle double-pile yarn bonded four-color jacquard double-pile knitting fabric and weaving method of the present invention. Detailed Implementation

[0054] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0055] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions shown in the attached diagram, while the terms “inside” and “outside” refer to the directions toward or away from the geometric center of a specific component, respectively. Example

[0056] To illustrate the knitting method of double-cut loop pile, the following knitting machine configuration is used as an example. On a double-needle bed cut loop pile knitting machine, the upper needle plate can be equipped with 4-needle row needles, which can be combined as required. The 4-needle row cams are arranged according to the requirements of double-cut loop knitting. The lower needle cylinder is arranged with cut needles according to the number of rows corresponding to the needles on the upper needle plate. When knitting jacquard cut loop pile, a two-station jacquard mechanism is configured. When knitting high and low pile fabrics, cut needles and cut needle cams that can be bent to different depths are configured.

[0057] 1. Production method of double-stage rear-stage synchronous loop cutting pile

[0058] for Figure 1 The structure shown is a two-needle fixed two-thread double-cut loop pile, and its knitting pattern is as follows: Figure 8 As shown, the upper needles of the knitting machine are arranged in a full AABB pattern, and the lower needle cylinder's cutter needles are arranged in the needle groove in an ab order corresponding to the needle intervals of BB and AA.

[0059] Now combined as follows Figure 2 The diagram showing the movement trajectories of the knitting needles and cutter needles illustrates the production method of post-processed, multi-step loop cutting:

[0060] In the first step, as the cylinder moves, the knitting needle enters section I. From the needle's trajectory line 1, it can be seen that the needle guide triangle acts on needles A and B, causing the needle to retract. Then, the ground yarn guide F... S Feed the ground yarn S onto the knitting needles. Then, the pressure triangle acts on needles A and B, causing the needles to be in a looped state (not slipping off), outside the upper needle cylinder opening line L1. In section I, the cutting needle is not working and is located at the lower needle cylinder opening line L3.

[0061] Step 2: When the knitting needle reaches section II, knitting needle A extends to the tuck position (without unhooking), while knitting needle B still holds the ground yarn S, opening the tab of needle A to create conditions for the knitting needle to lay the yarn. From the movement trajectory line 2 of the cutter needle, it can be seen that: cutter needle a and knitting needle A rise together to the yarn laying height, the plush yarn guide Fa feeds the plush yarn a into the knitting needle and cutter needle and lays the yarn. Under the action of their respective pressing triangles, the knitting needle is pressed to the loop position (the same position as the non-working needle B), and the tip of cutter needle a presses slightly above the back line L2 of the knitting needle.

[0062] When the knitting needle reaches section III, knitting needle B and cutter needle b work, and the rest of the process is the same as the operation of knitting needle A and cutter needle a in section II.

[0063] After passing through sections I, II, and III, the ground yarn and plush yarn complete the padding of the knitting needles AB and the cutting needles ab. At the same time, the yarn guide channels for the subsequent yarns of plush yarns a and b and ground yarn S are created.

[0064] Step 3: In the final stage of Part III, knitting needles AB continue to bend the yarn, loop, release, and form loops under the action of the pressure triangle, creating a plain knit yarn-adding structure. Simultaneously, cutting needles ab, under the action of the cutting needle pressure triangle, pull down the pile yarns a and b, forming loops. Complete. Figure 8 The medium-sized U-shaped plush yarn is woven in rows.

[0065] Step 4: When the knitting needles reach section IV, all needles AB participate in the work. After the needles straighten, the knitting yarn S is fed in. Then, the yarn is laid, bent, looped, released, and looped to complete the knitting of the plain knit rows. This achieves... Figure 8 The V-shaped rows of knitting. The needles do not participate in the work in this section.

[0066] Step 5: When knitting to section V, the pressing disc O holds down the loop yarns a and b, the cutting needle rises, and the blade cuts the loop yarns to form pile. After cutting the pile, the cutting needle returns to the needle barrel opening.

[0067] This completes one cycle of weaving for the two-thread cut loop pile.

[0068] 2. Production method of double-layer pre-processed step-by-step loop cutting pile

[0069] right Figure 1 The double-cut loop pile fabric can also be produced using the double-front step-by-step loop-forming method, and its weaving pattern is as follows: Figure 8 As shown. Now combined with Figure 3 The weaving method is explained below:

[0070] Step 1: When knitting to section I, the push-up cam simultaneously acts on knitting needle A, causing it to slip out of the loop; it also acts on cutter needle a, causing it to rise to the padding height. At this time, the pile yarn guide Fa feeds the pile yarn into knitting needle A and cutter needle a. Then, knitting needle A is pulled back to the loop position by the pressure cam (without slipping out of the loop), outside the upper needle cylinder opening line L1, holding the pile yarn a. Meanwhile, the cutter needle pressure cam continues to act, directly stretching the pile yarn a to the required pile yarn length, forming the final pile loop length.

[0071] Step 2: Knitting to section II, needles B and b, respectively, perform the same movements as needles A and b in step 1 using their respective cam systems. At this point, all the yarn a and b have been used to pad the yarn onto needles AB and to form loops with the broaching needles.

[0072] Step 3: Knitting to section III, with all needles AB in operation, the pile yarn is held in place by the special yarn retainer T, preventing it from protruding with the needles. The loops of pile yarn suspended on the needles open the latches of needles AB, placing the needles in the tucked position. At this point, the ground yarn guide F... S The yarn is then added to knitting needles AB, and then, under the action of the presser triangle, the knitting process of closing the loop, looping, loop removal, yarn bending, and loop formation is completed, forming a plain knit structure with added yarn, resulting in a stable plush yarn base structure. (Completed) Figure 8 The weave is in the middle U-shaped rows.

[0073] To ensure a smooth knitting process, when the knitting needle AB bends the yarn, the knife needle AB holding the yarn should be pulled back slightly to allow the knitting needle to obtain the yarn needed for bending.

[0074] Step 4: When the knitting needles reach section IV, all needles AB participate in the work. After the needles straighten, the knitting yarn S is fed in. Then, the yarn is laid, bent, looped, released, and looped to complete the knitting of the plain knit rows. This achieves... Figure 8 The V-shaped rows of knitting. The needles do not participate in the work in this section.

[0075] Step 5: When knitting to the V section, the pressing disc O holds down the loop yarn, the cutting needle rises, and the blade cuts the loop yarn in an arc to form the pile. After cutting the pile, the cutting needle returns to the needle barrel opening.

[0076] This completes one cycle of horizontal knitting of the two-thread cut loop pile.

[0077] 3. Production method of double-stage post-processed step-by-step loop cutting pile

[0078] for Figure 1 Double-cut loop pile fabric can also be woven using the double-back step-by-step loop-forming method, as shown in the weaving diagram. Figure 8 As shown, the weaving process is as follows (in conjunction with...) Figure 4 )illustrate:

[0079] Step 1: The knitting needles enter section I. All needles AB are pulled to the unwinding position by the action of the needle cam. The old loop is unwound from the needle hook onto the needle bar. The ground yarn guide F... S After feeding yarn to the knitting needle and applying pressure to the needle triangle, the ground yarn S is placed inside the needle hook. Then, the knitting needle AB is placed at the position of the needle plate opening loop, outside the needle plate cylinder opening line L1. The knitting needle AB holds the ground yarn S, completing the ground yarn padding process.

[0080] Step 2: The knitting needle enters section II. Knitting needle A, under the action of the cam, is pushed to the tuck position. The ground yarn S, still held by knitting needle B, opens the latch of knitting needle A. Simultaneously, the cutter needle a, under the action of the cam, rises to the yarn-cushioning height. The pile yarn guide Fa feeds yarn to knitting needle A and cutter needle a. Knitting needle A, under the action of the cam, completes the yarn-cushioning and puts the knitting needle into the loop state. Cutter needle a, under the action of the cam, descends. After cushioning the pile yarn, the needle tip is at the back line L2 of the knitting needle, completing the yarn-cushioning process of pile yarn a. The presser cam continues to act, pressing the cutter needle a to the maximum depth until the pile yarn loop is completed.

[0081] The knitting needle enters section III, and knitting needle B and cutter needle b repeat the actions of knitting needle A and cutter needle a in section II. After knitting in sections II and III, the back knitting of the plush yarn on cutter needle ab is completed.

[0082] Step 3: In the final stage of Part III, all needles a and b reach their lowest points. The knitting needles work together, and under the action of the pressure triangle, the old loops loop and unloop, while the new yarn (ground yarn, plush yarn) bends and forms loops. When knitting needles AB bend the yarn, needles a and b cooperate with a certain amount of backspin to facilitate smooth knitting. At this point, knitting needles AB have formed a loop with a yarn-adding plain knit structure. Completed. Figure 8 The weave is in the middle U-shaped rows.

[0083] Step 4: When the knitting needles reach section IV, all needles AB participate in the work. After the needles straighten, the knitting yarn S is fed in. Then, the yarn is laid, bent, looped, released, and looped to complete the knitting of the plain knit rows. This achieves... Figure 8 The V-shaped rows of knitting. The needles do not participate in the work in this section.

[0084] Step 5: When knitting to section V, the pressing disc O holds down the loop yarn, and the cutting needle ab rises, cutting the loop yarn in an arc to form the pile. After cutting the pile, the cutting needle ab returns to the needle barrel opening, positioned at line L3 on the needle barrel opening.

[0085] This completes one cycle of horizontal knitting of the two-thread cut loop pile.

[0086] 4. Dual-type pre-processed synchronous loop forming and cutting loop pile production method

[0087] for Figure 1Double-cut loop pile fabrics can also be knitted using a double-front synchronous loop-forming method. The knitting process is as follows:

[0088] Step 1: Knit to section I. Knitting needle A moves to the loop-off position, and cutting needle a rises to the yarn-cushioning height. The plush yarn guide Fa feeds yarn to both the knitting needle and the cutting needle. Under the action of the pressure cam, knitting needle A reaches the loop-closing position, and cutting needle a reaches the back of the knitting needle at L2. In this way, the plush yarn a completes the yarn-cushioning of knitting needle A and cutting needle a.

[0089] As we knit to section II, knitting needles B and cutter needles b repeat the corresponding actions of knitting needles A and cutter needles b, thus completing the padding of the plush yarn b onto the knitting needles and cutter needles. At this point, yarn guides Fa and Fb, knitting needles A and B, and cutter needles a and b form the yarn guiding channel for the plush yarn.

[0090] Step 2: Knit to section III, with needle AB raised to the tuck height. The plush yarn held by the cutter needle AB opens the needle latch of needle AB, and the ground yarn guide F... S With the yarn padding on knitting needles AB, under the action of the loop-forming triangle, knitting needles AB complete the looping, unlooping, bending, and looping of the ground yarn S and the pile yarn ab, forming a piled plain knit loop structure on knitting needles AB. Simultaneously, all the cutting needles ab, under the action of the pressing triangle, are pressed to their lowest position to form a loop arc. This achieves... Figure 8 The U-shaped weave in the middle.

[0091] Step 3: When the knitting needles reach section IV, all needles AB participate in the work. After the needles straighten, the knitting yarn S is fed in. Then, the yarn is laid, bent, looped, released, and looped to complete the knitting of the plain knit rows. This achieves... Figure 8 The V-shaped rows of knitting. The needles do not participate in the work in this section.

[0092] Step 4: When knitting to section V, press down the loop yarn with the pressure plate O, raise the cutting needle ab, and cut the loop yarn arc to form the pile. After cutting the pile, the cutting needle returns to the needle barrel opening L3.

[0093] This completes one cycle of horizontal knitting of the two-thread cut loop pile.

[0094] In this knitting method, in section II, the pile yarn can first form the final loop, and then in section III, a yarn stopper T can be installed to help the pile yarn open the needle latch (e.g., Figure 5 (As shown by the dotted line), when the knitting needles form a loop, the cutter needle cooperates with some backing to improve the knitting tension of the yarn. This cutter needle path can also complete this knitting row.

[0095] 5. Jacquard cut loop pile knitting method

[0096] In the four double-cut loop pile knitting methods described in 1-4 above, a needle selection mechanism is configured on the needles feeding the pile yarn to select the working state of the needles, which, in turn, assists in proper yarn threading, thereby realizing the production of jacquard loop pile. The knitting method is explained below:

[0097] In weaving Figure 8 In the cut-loop pile structure shown, treating ab as two different colored pile yarns creates a two-color cut-loop pile color-developing unit. This color-developing unit consists of 4 needles (AABB) and corresponds to 2 (ab) cutting needles. Within the same horizontal column, three combinations of cutting needles (a, b, or a+b) can be selected. This configuration makes the number of cutting needles half the number of knitting needles. This cutting needle / knitting needle configuration is denoted as a 2 / 4 combination, where 4 represents the color-developing unit width (number of needles), 2 represents the number of cutting needles within that unit, and the number of colors displayed for a single color.

[0098] When the needle is not selected for operation, the corresponding pile yarn is not stretched into a loop and only appears as a floating thread on the base fabric, forming a pile-up floating thread structure, without forming pile.

[0099] When only one needle (a or b) is selected in the color display unit, only one color (a or b) is displayed, resulting in a monochrome display area. When both needles (a, b, and a) are active in the display unit, two colors are displayed, creating a mixed-color area. When no needles are active in the color display area, it becomes a smooth (glossy) area. Using these four color combinations for two-color pattern design, the desired two-color jacquard loop pile can be produced.

[0100] When producing jacquard cut loop pile fabric, different color zones within the color-developing units are selected in different areas according to the pattern design requirements, thus forming the jacquard cut loop pile. When producing multi-color cut loop pile products, the color-developing units require a new design. (The last sentence appears to be incomplete and possibly refers to a knitting technique.) Figure 9 This yields a 3 / 6 configuration of tri-color jacquard cut loop pile. (Using knitting...) Figure 8 By performing two cycles, you can obtain a four-color jacquard cut loop pile with a configuration of 4 / 8.

[0101] use Figure 8 and 9 In the woven fabric structure, only one type (one strand) of pile yarn is inserted into each needle hook, forming a two-thread plain knit loop structure together with the ground yarn. To further increase the pile density, two types (two strands) of pile yarn can be inserted into one needle hook using a double-feed method, allowing the needle to knit a three-thread (double pile yarn) plain knit structure together with the ground yarn. The knitting pattern is as follows: Figure 10 , 11 As shown. Figure 10 This forms a three-color jacquard structure with a 3 / 3 configuration; Figure 11This forms a 4 / 4 four-color jacquard structure. Figure 11 By changing the yarn threading to an ab two-color cycle, you can obtain a configuration of 2 / 2 two-color jacquard cut loop pile.

[0102] exist Figure 10 and 11 In this process, the number of cutting needles and knitting needles are equal, resulting in a denser loop pile, which is more suitable for producing delicate, full, and thick loop pile products.

[0103] Using a double-layered pile yarn structure, and employing full-needle knitting with the same color yarn (as shown in Figures 10 and 11), high-density cut loop pile can be knitted using a two-needle fixed full-needle pile (one needle for each loop pile). When the pile height is appropriate, it can be made into a two-needle fixed velvet (a sheared product with single-sided loops), which avoids severe shedding.

[0104] Jacquard loop pile with a double-layered pile yarn structure is reliable in carpet products, with dense pile, which can reduce the carpet backing process.

[0105] In a double-pile yarn-added jacquard cut loop pile fabric, two pile yarns in a loop are cross-cut, meaning that only one pile yarn is cut within the same color unit, while the other is not. In this case, if a bottomless yarn is fed in, it can still be woven into a fabric, forming a bottomless jacquard cut loop pile fabric. However, when designing, care should be taken to use fewer small solid color blocks, avoid mixed color blocks and longitudinal stripes with large longitudinal lengths, so as not to affect the strength of the fabric and reduce its usability.

[0106] On a jacquard double-cut loop pile loom, replacing one or more sets of cut needles with latchless needles can produce a jacquard fabric interwoven with loop pile and terry loops. If all the cut needles are replaced with latchless needles, terry loop fabric can be knitted.

[0107] 6. Weaving method of high and low double-layer cut loop pile fabric

[0108] The weaving method of high-low compound cut loop pile is based on the weaving method of jacquard cut loop pile, except that the color in the color display unit is simply regarded as different lengths of pile yarn. When there is no needle working in the color display unit, it is called no pile. When displaying a, b, and c, they represent different pile lengths, with a being the longest and decreasing in that order. Patterns with different pile length areas can be designed on the fabric to form a raised jacquard pile fabric. Of course, it is also possible to regard a, b, and c as different colors at the same time, which can produce multi-color raised jacquard pile fabrics. When there are two or more pile heights in a color display unit, it is called a mixed pile length area.

[0109] Because of the different presser depths for different pile heights, the triangular system of the jacquard mechanism for high and low pile cut loop pile fabrics needs to be adjusted based on the jacquard mechanism for the same pile height in order to adapt to the weaving of high and low pile heights. The following are two examples: (1) Figure 6 The movement trajectory of a loop-forming machine component for a front-mounted, multi-step, high-low cut loop pile is such that the pressing depth of its cutting needle is divided into two heights. This can be achieved by adding a set of triangles with a smaller pressing depth to the jacquard machine. (2) Figure 7 The movement trajectory of a loop-forming machine component for a rear-mounted, double-synchronized, high-low cut loop pile is such that the needle pressing depth is divided into two heights. This can be achieved by configuring a set of thick and thin triangles with different pressing depths for different needles on a jacquard machine with needles of different lengths.

[0110] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, material, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, material, or apparatus.

[0111] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A weft-knitted double-loop pile fabric, knitted using a double-needle-bed circular weft-knitting double-loop pile knitting machine, wherein one needle bed is equipped with multi-needle knitting needles, and the other needle bed is equipped with cutting needles. The knitting needles and cutting needles, under the action of a dedicated cam system, knit the yarn fed by the yarn guide to form the fabric. The weft-knitted double-loop pile fabric is characterized by... It is woven from ground yarn and pile yarn. The ground yarn forms the base structure in the filler loop structure of the weft-knitted compound cut pile fabric. Each ground yarn forms a row of base structure. Multiple pile yarns participate in the knitting in a row of cut pile fabric. The number of knitting needles and non-knitting needles of each pile yarn are arranged alternately according to a certain ratio. Multiple pile yarns are arranged alternately to form a complete structure cycle. The pile yarns participating in the knitting are knitted together with the ground yarn to form filler loops to form fixed loops. The pile yarns not participating in the knitting become floats or are inserted into the cutter needles of another needle bed. The pile yarns inserted into the cutter needles are pulled into loops of the required length. During the operation of the loom, the cutter needles cut the loops to form cut pile rows. The cut pile rows are generally interwoven. The horizontal rows of the knitted structure are completed by knitting needles. The weft-knitted double-cut loop pile fabric is formed by different combinations of double-cut loop pile forming machines to form different fabrics, including solid color pile fabric, jacquard pile fabric, and high-low pile fabric. Different combinations of double-cut loop pile forming machines result in different knitting methods, including the back-position double-cut synchronous loop knitting method where the pile yarn is later than the ground yarn and multiple pile yarns form loops simultaneously; the front-position double-cut synchronous loop knitting method where the pile yarn is earlier than the ground yarn and multiple pile yarns form loops simultaneously; the double-cut loop pile knitting method where multiple pile yarns form loops separately; the jacquard double-cut loop pile knitting method where a needle selection mechanism is used to select the cutting needles to form loops; and the high-low double-cut loop pile knitting method that achieves different pile lengths based on the jacquard double-cut loop pile knitting method.

2. The weaving method for weft-knitted double-cut loop pile fabric according to claim 1, characterized in that, The aforementioned post-positioned, compound, synchronous loop-forming knitting method specifically refers to: (1) After all the knitting needles have come off the loop, the ground yarn guide feeds in the ground yarn. After the pressure triangle is activated, the ground yarn is inserted into the knitting needle. The knitting needle is pressed to the loop position, and the needle hook holds the ground yarn. (2) Some knitting needles are pushed to the tucked position under the action of the cam, while the other knitting needles still hold the ground yarn, which remains straight. The ground yarn opens the needle tongue of the knitting needles that have been pushed to the tucked position. At the same time, some of the cutter needles that are paired with these knitting needles also move to the padding position. The yarn guide feeds yarn to these knitting needles and cutter needles. The knitting needles and cutter needles are pressed down by their respective cams. The yarn is padded into the hooks of the knitting needles and cutter needles. The cams work further to make the knitting needles hold the yarn and return to the looping position. When the cutter needle is positioned flush with the other knitting needles and spaced apart from the knitting needles, the cutter needle holds the yarn at the back of the knitting needle. The goal is to ensure that the yarn is stably held by the knitting needle under low tension and to prevent collision between the knitting needle and the cutter needle. This completes the padding of one pile yarn. Repeat this process for other combinations of knitting needles and cutter needles to feed and pad multiple pile yarns. At this point, the yarn guide, knitting needle hook, and cutter needle hook form a yarn guide channel for knitting a row of pile yarns. (3) After the ground yarn and plush yarn are placed on the knitting needle and the cutting needle, the yarn is bent into a loop on the knitting needle by the pressure needle triangle to form a flat needle yarn loop. At the same time, all the cutting needles will form the plush yarn into an elongated loop arc under the action of the triangle, thus completing the knitting of the cut loop plush horizontal row. (4) All knitting needles work again to knit the plain fabric in the horizontal rows, while the knife needles do not participate in the work; (5) Press down the long loop of fluffy yarn formed on the cutting needle with the pressing plate. The cutting needle is acted by the triangular action of the needle and cuts the loop with the blade to form fluff. If the cutting needle is a combination cutting needle, the pressing plate is not needed, and the blade of the cutting needle is used directly to cut the loop.

3. The weaving method for weft-knitted double-cut loop pile fabric according to claim 2, characterized in that, The aforementioned pre-positioned, double-layered, synchronous loop-forming knitting method specifically refers to: (1) Some knitting needles and corresponding cutting needles are lifted by their respective triangles. The knitting needles are lifted to the loop position, and the cutting needles are lifted to the yarn padding position. The yarn guide feeds the knitting needles and cutting needles with fluffy yarn at the same time. Then the pressing triangle presses the knitting needles to the loop position and the cutting needle head is pressed to the back of the knitting needle, thus completing the yarn padding of the fluffy yarn to the knitting needles and cutting needles. The other part of the knitting needles and corresponding cutting needles repeat this process of padding fluffy yarn, that is, the multiple fluffy yarns are padded to different knitting needles and cutting needles. After the yarn padding is completed, the yarn guide, the knitting needle hook and the cutting needle hook construct the fluffy yarn guiding channel. (2) The needles are pushed to the tuck position by the action of the needle-lifting triangle. The yarn guide feeds the ground yarn into the needles only. Then the needles and the cutter needles are pressed by the action of the needle-pressing triangle. The needles complete the ground yarn padding and bend the yarn into loops together with their respective pile yarns to form a flat needle padded yarn structure. The cutter needles simultaneously form the pile yarn into an elongated loop arc to complete the knitting of the cut pile horizontal row. (3) All knitting needles work again to knit the plain fabric in the horizontal rows, while the knife needles do not participate in the work; (4) Press down the long loop of fluffy yarn formed on the cutting needle with the pressing plate. The cutting needle is cut off by the cutting edge of the cutting needle triangle to form fluff.

4. The weaving method of the weft-knitted double-cut loop pile fabric according to claim 3, characterized in that, The aforementioned compound step-by-step loop knitting method specifically refers to the following: based on the two methods of rear compound synchronous loop knitting and front compound synchronous loop knitting, after each feeding of pile yarn is placed on the cutting needle, the cutting needle continues to be pressed to the final required depth by the action of the pressure needle triangle, forming an elongated pile yarn loop arc. That is, the loop arc formation of each pile yarn is carried out separately. When using this step-by-step loop knitting method, when the knitting needle enters the loop formation stage, the cutting needle needs to retract to a certain extent to provide the knitting needle with the required yarn for the pile yarn to form a loop.

5. The weaving method for weft-knitted double-cut loop pile fabric according to claim 4, characterized in that, The specific knitting method of jacquard double-cut loop pile refers to the following: based on the rear double-synchronous loop knitting method, the front double-synchronous loop knitting method, and the double-step cut loop pile knitting method, different colored yarns are used for the pile yarns fed in a horizontal row, and the cutting needles within a cycle width correspond to different colored yarns. To obtain a single-color block in jacquard cut loop pile, only one colored yarn corresponding to the cutting needles arranged within a cycle width must work to form pile. Pile yarns that do not form pile are not cut by the cutting needles at that position and only form floats. The yarn is covered by the formed colored plush, and is located inside the colored plush, thus obtaining a single-color colored area. This requires selective needle release from a cyclically arranged needle. During knitting, a weft knitting needle selection mechanism is used, which can be selected from mechanical and electronic needle selection mechanisms. When knitting with a needle selection mechanism, the pressing action of the needle is generated by the action of the pressing triangle of the needle against the needle heel; the needle release action is completed by the needle selection mechanism. In this way, the color can be specified for each colored unit as needed, thus obtaining multi-color jacquard loop pile with various patterns.

6. The weaving method for weft-knitted double-cut loop pile fabric according to claim 5, characterized in that, The high-low double-loop pile knitting method specifically refers to: various pile heights of pile fabrics forming a certain pattern, with some areas of the pattern being high pile and others being low pile, or even no pile, thus creating a three-dimensional pattern with a raised effect. To obtain high-low double-loop pile, the pile yarn feeding system must be equipped with at least two needle selection mechanisms, meaning the loom must have the function of a jacquard double-loop pile machine, and be equipped with cutting needles and a cutting needle cam system capable of knitting high and low pile heights. Therefore, the knitting of high-low double-loop pile is achieved by constructing the needle path of high and low pile heights on the basis of jacquard double-loop pile; in the step-by-step loop knitting system, a... The first yarn fed into the row is pressed to the deepest position by the pressure triangle of the selected needle, forming the longest pile loop. The pressure depth of the next yarn fed in gradually decreases, and so on, to obtain pile heights of different lengths. After cutting the loops, high and low pile pile is formed. In the synchronous loop knitting system, the needle feet are designed with different heights, and the pressure triangles of the needles are corresponding to them with different thicknesses. At the same time, the pressure depth of the pressure triangles of different thicknesses is designed to the required value. The longer the needle foot, the deeper the pressure depth, the longer the loop formed, and the higher the pile formed after cutting the loops. This is how high and low pile pile is formed.

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