Air-warming fabric and weaving method thereof, and air-warming clothing

Abstract

The present invention discloses an air-warming fabric and a weaving method thereof, and air-warming clothing, belonging to the field of textiles. The air-warming fabric includes an outer layer of cloth, which needs to be covered with an inner layer of cloth on the back of the outer layer of cloth when in use. The outer layer of cloth includes a filling area and a connecting belt surrounding the filling area. In the filling area, a bottom yarn and a face yarn are woven into a surface layer. The filling yarn forms floating threads on the back of the surface layer, and the end points of the filling yarn serving as the floating threads are fixed to the connecting belt. The filling yarn is connected to the fabric, so the problem of fleece during exercise will not occur. After washing and drying, the fabric can be easily and distinctly spread out again. The outer layer of cloth and the inner layer of cloth protect the floating threads of the filling yarn in the middle. The filling yarn suppresses air flow between the outer layer of cloth and the inner layer of cloth, thereby achieving warmth retention, and eliminating the need for refilling in the later stages of clothing production.

Description

Technical Field

[0001] The invention relates to an air-warming fabric and a weaving method thereof, and air-warming clothing, belonging to the field of textiles. Background Art

[0002] The thermal conductivity of still air is even lower than that of ordinary fibers. For example, the principle behind down-filled, air-warming clothing, such as padded and down jackets, is to use the down to trap as much air as possible, increasing thickness and thermal resistance without adding weight. Existing padded jackets use down to create a bulge between the inner and outer layers, trapping air between them and providing warmth. However, because the cotton lint enters the clothes through filling and has no connection with the inner and outer layers of the clothes, the cotton clothes in the prior art have the following disadvantages: First, for downstream garment factories, the fillers and the inner and outer layers of the clothes are purchased separately and filled in during the clothing-making process. During the clothing-making process, special attention needs to be paid to the amount of filling and whether the filling is evenly distributed, which makes the clothing-making process more cumbersome; Second, for users, the fillers are easy to fall off the clothes during exercise. The longer the clothes are used, the more lint will come out, resulting in a gradual decrease in the warmth-keeping ability of the clothes; Third, air-insulated clothes are inconvenient to wash. In addition to the lint coming out, the washing process will cause the fillers to gather into lumps, which are still difficult to disperse again even after drying. The degree to which the fillers support the inner and outer layers of the clothes is reduced, which reduces the warmth-keeping performance. The clothes also feel worse due to the lumpy feeling inside. Summary of the Invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides an air-warming fabric and a weaving method thereof, wherein a filler is woven together during the weaving process, and provides an air-warming garment that does not shed and is easy to wash.

[0004] The technical solution adopted by the present invention to solve its technical problem is:

[0005] In a first aspect, the present application provides a method for weaving an air-warming fabric, the steps comprising: weaving an outer layer of fabric;

[0006] Filling yarn, face yarn and bottom yarn are used when weaving the outer cloth. The outer cloth includes a filling area and a connecting belt surrounding the filling area. When weaving the filling area, the bottom yarn and the face yarn are woven into a surface layer. The filling yarn forms a floating line on the back of the surface layer, and the end point of the filling yarn serving as the floating line is fixed on the connecting belt.

[0007] The weaving method of the air-warming fabric provided by the present application uses the filling yarn floating threads on the back of the outer cloth instead of the additional filling material. The filling yarn is occasionally looped at the connecting belt to achieve fixation. In actual application, it is necessary to cover the inner cloth on the back of the outer cloth (that is, the side with the floating threads). The edge of the inner cloth is connected and fixed to the edge of the outer cloth. The filling yarn is connected to the outer cloth, and there is no problem of fleece running during exercise. It is also easy to spread out again after washing and drying. The outer cloth and the inner cloth protect the floating threads of the filling yarn in the middle, and there is no need to worry about the floating threads being hooked when wearing or washing. The filling yarn suppresses the air flow between the outer cloth and the inner cloth, so it has a warming effect close to that of general down-filled air-warming clothing, and there is no need to fill down in the later clothing making stage.

[0008] Furthermore, when weaving the connecting belt, at some positions, the filling yarn and the bottom yarn are looped at the same time, and the surface yarn is a floating yarn to form a positioning point; at other positions, the filling yarn, the bottom yarn and the surface yarn are all floating yarns to form a shortcoming, and there is at least one positioning point on any row of the connecting belt to fix the end point of the filling yarn.

[0009] The connecting belt has parts where the three yarns are not looped, and parts where the filling yarn and the bottom yarn are looped at the same time, which makes the connecting belt shrink more strongly than the filling area. The connecting belt is subject to a greater constraint force to form a quilting effect. The filling area is less constrained and is surrounded by the more constrained connecting belt, so that it bulges outward, leaving a larger space between the outer cloth and the inner cloth to retain air, making the fabric of the same weight thicker, and the space between the outer cloth and the inner cloth larger, so that the filling yarn can be used to retain more air, thereby achieving the warmth-keeping effect of general down-filled air-insulating clothing.

[0010] Furthermore, the connecting belt includes a plurality of continuous connecting units, and each of the filling yarns is looped at least once at a location where it overlaps with the connecting unit.

[0011] Furthermore, each of the connection units includes at least two rows and at least two columns.

[0012] Furthermore, the filling yarn, face yarn and bottom yarn meet at least one of the following requirements:

[0013] A. The elasticity of the filling yarn is stronger than that of the base yarn and the face yarn;

[0014] B. After the filling yarn, face yarn and bottom yarn are subjected to the same heating treatment, the shrinkage of the filling yarn is stronger than that of the face yarn and the bottom yarn;

[0015] C. After the filling yarn, face yarn and bottom yarn are treated with the same solution, the shrinkage of the filling yarn will be stronger than that of the face yarn and the bottom yarn.

[0016] When the elasticity or shrinkage of the filling yarn is stronger than that of the base yarn and the face yarn, the shrinkage difference between the connecting belt and the filling area will be enhanced, causing the filling area to bulge outward more strongly, leaving more space for air retention between the outer and inner fabrics, and achieving better warmth retention.

[0017] Furthermore, the filling yarn is a hollow bulked yarn.

[0018] Hollow bulked yarn has the characteristics of low density and hollow warmth. When used as a floating line between the outer cloth surface and the inner cloth, it can better simulate the effect of fluff filling. The hollow bulked yarn itself is elastic, and at the same time meets the needs of light weight, warmth and elasticity.

[0019] Regarding requirement A, preferably, the elongation of the filling yarn is 1.2 to 2.5 times that of the higher one of the ground yarn and the face yarn.

[0020] The stronger the elasticity of the filling yarn, the greater the difference in shrinkage between the connecting band and the filling area. However, if the filling yarn is too elastic compared to the base and face yarns, the floating tension in the filling area will be excessive, causing the filling area to deform and shrink, which is detrimental to the filling area's outward bulging. More preferably, both the base and face yarns are non-stretch yarns, and the elongation of the filling yarn is 120%-250%.

[0021] Regarding requirements B and C, after undergoing the same treatment, the filling yarn has greater elasticity than the ground yarn and the face yarn, and the shrinkage of the filling yarn is 1.2 to 2.5 times the higher of the ground yarn and the face yarn. Shrinkage = (natural length - length after treatment) / natural length * 100%. Washing should be considered a solution treatment, and drying should be considered a heat treatment.

[0022] More preferably, the number of needles of the applicable knitting machine is above 28, the count of the face yarn is above 26S, and the denier of the base yarn is 10D-75D. The product woven by the method of the present application does not need to be prevented from running through a dense surface like down. The face yarn is made of yarn with a density of 26S or above, which helps to avoid the total mass of the face yarn and the base yarn accounting for too much of the mass of the entire fabric, making the fabric lighter and thinner. In conjunction with the face yarn and the base yarn, the filling yarn is a fine denier yarn with a fineness of 1.0dpf-2.4dpf or an ultra-fine denier yarn with a fineness of 0.3dpf-1.0dpf. The filling yarn of this specification makes the shrinkage difference between the filling area and the connecting belt after washing the fabric more obvious, and makes the filling area bulge more strongly.

[0023] Furthermore, the weaving method of the air-warming fabric is applicable to a seamless circular knitting machine, and the step of weaving the outer layer of fabric comprises:

[0024] Weave the inner and outer layers of fabric connected top to bottom, align the floating yarn of the filling yarn with the inner fabric, and connect the inner and outer fabrics end to end.

[0025] When used, the outer fabric needs to be covered with the inner fabric on the back, and the edges of the inner fabric must be connected and fixed to the edges of the outer fabric. In addition, during the production process, the fabric needs to be washed and dried after it comes off the machine, and the back of the outer fabric needs to be protected. If the outer and inner fabrics are woven separately and then the edges of the outer and inner fabrics are sewn together, the fabric shrinks significantly after washing, while the sewing thread shrinks little, requiring the stitches to be removed and sewn again, which is a complicated process. Using a seamless circular knitting machine, the inner and outer fabrics are continuously woven and then connected end to end. The inner and outer fabrics can then be washed and used in garment making after washing, which helps reduce the number of steps after coming off the machine.

[0026] Furthermore, the inner layer of fabric is a weft-woven fabric formed by looping the bottom yarn and the surface yarn simultaneously, which is not only conducive to storing air in cooperation with the outer layer of fabric, but also can provide a smooth inner surface.

[0027] Furthermore, the number of columns when the inner layer cloth is woven is the same as the number of columns when the outer layer cloth is woven, and the number of rows when the inner layer cloth is woven is smaller than the number of rows when the outer layer cloth is woven.

[0028] The inner and outer fabrics are joined end to end to form a circular fabric blank. In addition to the connecting band, elastic filling yarn increases the difference in shrinkage between the inner and outer fabrics, favoring the outer fabric's greater shrinkage. The fewer rows of inner fabric than the outer fabric ensures that the actual height of the inner and outer fabrics is similar, making the circular fabric blank entirely outer fabric on the outward side and inner fabric on the inward side. When the inner fabric is a plain weft fabric, the inward side consisting entirely of inner fabric provides a smooth inner surface, while the outward side consisting entirely of outer fabric creates a bulged structure and an appearance similar to that of ordinary down-filled garments.

[0029] Furthermore, the steps of weaving an inner layer of cloth and an outer layer of cloth connected to each other, aligning the floating yarn of the filling yarn with the inner layer of cloth, and connecting the inner layer of cloth and the outer layer of cloth end to end include:

[0030] The lower needle of the seamless circular knitting machine starts knitting, and after knitting a starting section with a first number of rows using the bottom yarn and the top yarn, the upper needle and the lower needle of the seamless circular knitting machine simultaneously hook a row of yarn, and then the upper needle keeps holding the loop, while the lower needle continues knitting;

[0031] Then the stitch held by the upper needle is transferred to the lower needle, and the lower needle uses the ground yarn and the top yarn to knit an ending section with a second number of rows;

[0032] Wherein, the lower needle continues knitting including: knitting the outer layer of cloth first and then knitting the inner layer of cloth, or knitting the inner layer of cloth first and then knitting the outer layer of cloth;

[0033] The cloth woven in this specific step is a cylinder with a filling effect when it comes off the machine, and it is seamless in the up and down directions and the left and right directions, which makes it convenient to directly wash the cloth. The filling yarn is protected between the surface of the outer cloth and the inner cloth, and there is no need to worry about the floating thread being broken during the subsequent washing and drying steps. In addition, the cloth off the machine can be directly used as the main body of the top, and the sleeves can be attached to make clothes, which greatly reduces the steps in the subsequent clothing making process.

[0034] In the second aspect, the present application provides an air-warming fabric, comprising an outer layer of cloth, wherein the outer layer of cloth is a weft-knitted fabric comprising filling yarn, base yarn and face yarn, the outer layer of cloth comprising a filling area and a connecting belt surrounding the filling area, the filling area comprising a surface layer, and floating lines formed by the filling yarn being arranged across the back of the surface layer, the endpoints of each floating line formed by the filling yarn in the filling area being fixed on the connecting belt.

[0035] In actual application, the inner layer of fabric needs to be covered on the back of the outer layer of fabric, and the edges of the inner layer of fabric are connected and fixed to the edges of the outer layer of fabric. In the filling area, the filling yarn takes the form of floating threads, replacing the additional down that is usually added to plush garments. The floating threads of the filling yarn are located on the side of the outer layer of fabric facing the inner layer of fabric, that is, in the middle of the fabric, which can hinder air flow and achieve warmth. The filling yarn is connected to the outer layer of fabric, so there will be no problem of down running. The filling yarn is not exposed and there is no need to worry about it being snagged, so it is not afraid of washing. After washing and drying, the floating threads of the filling yarn are easy to spread out clearly. The fabric already has filling yarn inside after weaving, and there is no need for later filling, which can greatly reduce the process of downstream clothing production.

[0036] Furthermore, the connecting belt includes a positioning point and a shortcoming, at the positioning point, the filling yarn and the bottom yarn are looped at the same time, and at the shortcoming, the filling yarn, the bottom yarn and the surface yarn all form floating threads; all the floating threads in the filling area and the connecting belt are located on the side of the outer layer of cloth facing the inner layer of cloth.

[0037] The positioning points in the connecting belt fix the two ends of the filling yarn floats in the filling area. The shortcoming will shrink after leaving the machine, making the shrinkage of the connecting belt stronger than that of the filling area. The connecting belt surrounds the filling area, and the difference in shrinkage causes the filling area to bulge and store air.

[0038] Furthermore, the air-warming fabric further comprises an inner layer of cloth, which is connected end to end with the outer layer of cloth, and all the floating threads in the filling area and the connecting belt are located on the side of the outer layer of cloth facing the inner layer of cloth.

[0039] There is no need for downstream garment factories to select inner layers and sew the edges of outer and inner layers together, and garments can be cut directly. For weaving factories, this simplifies the post-loom processing steps.

[0040] Furthermore, the connecting belt includes a plurality of continuous connecting units, and each of the filling yarns is looped at least once at a location where it overlaps with the connecting unit.

[0041] Furthermore, each of the connecting units includes at least two rows and at least two columns, so that the connecting belt can meet the above positioning point and point distribution requirements while also imitating a quilting effect in appearance.

[0042] Furthermore, the connection unit is four to eight rows high and four to eight columns wide. In each connection unit, on the same column, there is at least one said saving defect in two adjacent rows of any said positioning point; on the same row, there is at least one said saving defect in two adjacent columns of any said positioning point.

[0043] This distribution allows the filling yarn floats in each filling area to be fixed at the edge of the filling area, and ensures that the shrinkage of the connecting belt is significantly stronger than the filling area, which is conducive to the filling area of ​​the fabric to naturally swell up again after washing and drying.

[0044] Furthermore, the filling yarn, face yarn and bottom yarn meet at least one of the following requirements:

[0045] A. The elasticity of the filling yarn is stronger than that of the base yarn and the face yarn;

[0046] B. After the filling yarn, face yarn and bottom yarn are subjected to the same heating treatment, the shrinkage of the filling yarn is stronger than that of the face yarn and the bottom yarn;

[0047] C. After the filling yarn, face yarn and bottom yarn are treated with the same solution, the shrinkage of the filling yarn will be stronger than that of the face yarn and the bottom yarn.

[0048] When the elasticity or shrinkage of the filling yarn is stronger than that of the base yarn and the face yarn, the shrinkage difference between the connecting belt and the filling area will be enhanced, causing the filling area to bulge outward more strongly, leaving more space for air retention between the outer and inner fabrics, and achieving better warmth retention.

[0049] Furthermore, the filling yarn is a hollow bulked yarn.

[0050] Regarding requirement A, preferably, the elongation of the filling yarn is 1.2 to 2.5 times that of the higher one of the ground yarn and the face yarn.

[0051] Regarding requirements B and C, after receiving the same treatment, the filling yarn has stronger elasticity than the base yarn and the face yarn, and the shrinkage rate of the filling yarn is 1.2 to 2.5 times that of the higher shrinkage rate of the base yarn and the face yarn.

[0052] Furthermore, the count of the face yarn is above 26S, and the denier of the base yarn is 10D-75D.

[0053] Furthermore, the filling yarn is a fine denier yarn with a fineness of 1.0 dpf-2.4 dpf or an ultra-fine denier yarn with a fineness of 0.3 dpf-1.0 dpf.

[0054] Furthermore, the number of weaving columns of the inner layer cloth is the same as the number of weaving columns of the outer layer cloth, and the number of weaving rows of the inner layer cloth is less than the number of weaving rows of the outer layer cloth.

[0055] In a third aspect, the present application provides an air-warming garment comprising the air-warming fabric as described in the second aspect.

[0056] The beneficial effects of the present invention are as follows: the present invention uses the filling yarn floating threads on the back of the outer cloth to replace the additional filling material. The filling yarn is connected to the outer cloth, and the problem of fleece during exercise will not occur. It is also easy to spread out again after washing and drying. The outer cloth and the inner cloth are connected end to end, and the floating threads of the filling yarn are protected in the middle. There is no need to worry about the floating threads being hooked when wearing or washing. The filling yarn inhibits the air flow between the outer cloth and the inner cloth, replacing the filling material of general air-warming clothing to achieve warmth.

[0057] Other features and advantages of the present application will be described in the following description, and in part will become apparent from the description, or understood by practicing the present application. The purpose and other advantages of the present application can be realized and obtained by the structures particularly pointed out in the written description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1 This is a diagram of the action process of a seamless circular knitting machine in a weaving method for an air-warming fabric provided in an embodiment of the present application.

[0059] Figure 2 This is a structural diagram of an air-warming fabric provided in an embodiment of the present application after being taken off the machine.

[0060] Figure 3 This is an organizational structure diagram of a connection unit in the connection belt provided in an embodiment of the present application.

[0061] Figure 4 This is a schematic diagram of the minimum cycle structure of an outer layer cloth provided in an embodiment of the present application.

[0062] Figure 5 This is a schematic diagram of the local organizational structure of an outer layer cloth provided in an embodiment of the present application.

[0063] Figure 6 This is a physical picture of the outward-facing side of an air-warming fabric provided in an embodiment of the present application.

[0064] Figure 7This is a physical picture of the inner side of an air-warming fabric provided in an embodiment of the present application.

[0065] Figure 8 It is a design drawing of various organizational structures that can be used as the surface layer of the filling area.

[0066] Reference numerals: 1, outer layer of cloth; 12, filling area; 11, connecting belt; 2, inner layer of cloth. DETAILED DESCRIPTION

[0067] The embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and are not to be construed as limiting the present invention.

[0068] The following disclosure provides many different embodiments or examples for implementing different structures of the present invention. To simplify the disclosure of the present invention, the components and configurations of specific examples are described below. Of course, these are merely examples and are not intended to limit the present invention. In addition, the present invention may repeat reference numbers and / or reference letters in different examples. Such repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or configurations discussed.

[0069] Increasing the thickness of insulation is a common method for improving thermal resistance and thus the warmth of clothing. Ideally, the thickness of clothing should be increased but the overall mass should be minimized. Still air has a lower thermal conductivity than conventional yarn, and its density is much lower. Therefore, still air is an ideal insulating material for clothing. Down-filled clothing is a prime example of this, using fillings such as cotton wool and duck down to restrict air flow, resulting in minimal weight gain and significantly improved warmth. However, prior art down-filled clothing has several issues. For garment manufacturers, the production process is cumbersome; for users, down easily sheds during exercise, and the warmth retention is difficult to restore after washing.

[0070] In response to these problems, an embodiment of the present application provides a method for weaving an air-warming fabric, the steps comprising: weaving an outer layer of fabric;

[0071] Filling yarn, face yarn and bottom yarn are used when weaving the outer cloth. The outer cloth includes a filling area and a connecting belt surrounding the filling area. When weaving the filling area, the bottom yarn and the face yarn are woven into the surface layer. The filling yarn forms a floating line on the back of the surface layer, and the end point of the filling yarn serving as the floating line is fixed on the connecting belt.

[0072] When used, the inner cloth needs to be covered on the back of the outer cloth, and the edge of the inner cloth is connected and fixed to the edge of the outer cloth. The principle of achieving warmth preservation in the embodiment of the present application is: there is air between the outer cloth and the inner cloth, and the floating yarn of the filling area suppresses the air flow between the outer cloth and the inner cloth to achieve warmth preservation.

[0073] On this basis, the advantages of the embodiments of the present application over conventional down-filled garments are: the filling yarn is connected to the outer fabric, preventing down from running during exercise, and the fabric easily and distinctly unravels after washing and drying. The warmth retention effect is achieved right off the machine, eliminating the need for post-processing (setting, fleecing, dyeing), and eliminating the need for down filling in the later stages of garment production. This significantly reduces the number of steps required by garment factories, which only need to cut and sew to create finished garments, eliminating the need to purchase additional filling materials or down filling.

[0074] Those skilled in the art will understand that long floating threads are easily snagged and cut during wearing or washing. However, the outer layer of cloth and the inner layer of cloth are connected to protect the floating threads of the filling yarn in the middle, so there is no need to worry about the floating threads being snagged and cut during wearing or washing.

[0075] In a preferred embodiment, when weaving the connecting belt, at some positions, the filling yarn and the bottom yarn are looped at the same time, and the face yarn is a floating yarn to form a positioning point; at other positions, the filling yarn, the bottom yarn and the face yarn are all floating yarns to form a shortcoming.

[0076] The principle of achieving the same warmth-keeping effect as general plush-filled garments in this embodiment is that the filling yarn is occasionally looped at the connecting band to achieve fixation. The connecting band has both parts where the three yarns are not looped and parts where the filling yarn and the bottom yarn are looped at the same time, so that the shrinkage degree of the connecting band is stronger than that of the filling area. The connecting band is subject to a greater constraint force to form a quilting-like effect, while the filling area is less constrained and is surrounded by the more constrained connecting band, thereby bulging outward.

[0077] Prior art down-filled garments use stitching to separate the garment into sections to prevent the filling from gathering due to gravity. The stitching passes through both the outer and inner layers, resulting in bulges on both the inner and outer surfaces. In the embodiments of the present application, the filling yarn and the inner fabric do not need to be connected. The connecting band is present on the outer fabric, and the inner fabric only needs to be connected to the edge of the outer fabric. A simple plain weave or plain woven fabric can be used as the inner fabric, resulting in a smooth inner fabric surface and bulges only on the outer fabric surface, which promotes a comfortable wearer's feel.

[0078] The organizational structure of the surface layer of the filling area has various forms. At least in some positions of the filling area, the surface yarn and the bottom yarn are looped at the same time, such as Figure 8 As shown, for example Figure 8 The plain weave structure at a, Figure 8 The checkerboard complementary organization structure at b, Figure 82×1 right twill structure at c, Figure 8 1×1 false rib structure at d, Figure 8 2×1 false rib structure at e, Figure 8 1×1 false rib interlaced structure at f, Figure 8 3×1 right twill structure at g, Figure 8 The herringbone twill structure at h. Among them, the surface layer woven with plain weave structure has the best effect.

[0079] When used, the outer fabric needs to cover the inner fabric on the back, with the edges of the inner fabric connected and fixed to the edges of the outer fabric. Furthermore, during the production process, the fabric needs to be washed and dried after it leaves the machine, and the back of the outer fabric needs to be protected. If the outer and inner fabrics are woven separately and then the edges of the outer and inner fabrics are sewn together, the fabric shrinks significantly after washing, while the sewing threads shrink little, requiring the stitches to be removed and sewn again, which is a complex process. In a preferred embodiment, the inner and outer fabrics are woven together, and then the inner and outer fabrics are connected end to end with all floating threads on the outer fabric facing the inner fabric. This allows a specific weaving method to make the entire fabric completely seamless.

[0080] For example, when starting to weave, the half needle is activated so that the yarn is simultaneously strung on the knitting needle of the lower needle cylinder and the half needle of the upper needle disk. The half needle is retracted to hold the yarn, and the knitting needle of the lower needle cylinder continues to weave. When the inner layer of fabric ends, the half needle is removed and the held coil is moved to the knitting needle of the lower needle cylinder, so that the inner and outer layers are connected from beginning to end.

[0081] Specifically, the lower needle of the seamless circular knitting machine starts knitting, using the ground yarn and the top yarn to knit a starting section with a first number of rows. Then, the upper needle and the lower needle of the seamless circular knitting machine simultaneously pick up a row of yarn. The upper needle then keeps holding the loop while the lower needle continues knitting. The loop held by the upper needle is then transferred to the lower needle, which uses the ground yarn and the top yarn to knit a final section with a second number of rows. The first number of rows is 2 or more, and the second number of rows is 2 or more.

[0082] Wherein, continuing to knit with the lower needle includes: knitting the outer layer first and then the inner layer, or knitting the inner layer first and then the outer layer. In some embodiments, the yarn specifications of the inner layer and the outer layer may be different. For example, when knitting the outer layer first and then the inner layer, a ground yarn of a first specification and a face yarn of a second specification are selected when knitting the outer layer. After knitting the outer layer, the ground yarn of the first specification is retained and replaced with a face yarn of a third specification. The last row of loops of the outer layer is looped and the inner layer is knitted, so that the outer layer and the inner layer have different textures.

[0083] Reference Figure 1The weaving direction is from bottom to top. Process A (the letters represent only the movements of the seamless circular knitting machine; not necessarily one letter corresponds to one row of yarn) and process B represent the bottom needle of the seamless circular knitting machine starting to knit the starting section. Process A means that the first row of the ground yarn and the top yarn are looped simultaneously every other stitch (sometimes called a column), and process B means that the second row of the ground yarn and the top yarn are looped simultaneously every column. Process A corresponds to one row of yarn (in this embodiment, more specifically, one top yarn plus one ground yarn), and process B corresponds to one row of yarn. Process C represents the third row of the seamless circular knitting machine where the top and bottom needles simultaneously engage the yarn. In this embodiment, the first row number is 2, namely A and B, which prevents the yarn from falling apart. Process C corresponds to one row of yarn. Process D indicates that the top needle maintains its grip on the third row of loops while the bottom needle continues knitting, including knitting the outer layer first and then the inner layer, or knitting the inner layer first and then the outer layer. Therefore, process D includes over a hundred rows of yarn, and the specific number of rows depends on the preset height of the fabric. The E stage indicates that both the outer and inner fabrics have been knitted, and the loops held by the upper needle are transferred to the lower needle. This is merely a transfer process; no new yarn is woven in. The E stage corresponds to row 0. The F stage indicates that the lower needle has knitted in a row of yarn. Before the E stage, the lower needle holds the last row of loops for the outer or inner fabric. After the E stage, a third row of loops is added, transferred from the upper needle. Each lower needle has two loops, so the F stage is double-looped. After a new row of yarn is woven in, the loops return to single-looped loops. The F stage corresponds to a row of yarn. The G and H stages indicate the end stages. The G stage forms loops simultaneously for every other stitch in the first row of the ground and top yarns. The H stage forms loops simultaneously for every row in the second row of the ground and top yarns, preventing unraveling. The G stage corresponds to a row of yarn, and the H stage corresponds to a row of yarn. At this point, the fabric can be removed from the machine.

[0084] The resulting fabric structure is as follows Figure 2 As shown, the horizontal direction is a loop ( Figure 2 In order to show the inner layer of fabric, a hole was cut. Figure 1 It is not a continuous loop in the horizontal direction. The actual cloth coming off the machine is a continuous loop, that is, it is seamless in the left and right directions. It is also a loop in the vertical direction, that is, it is seamless in the up and down directions. The inner layer of cloth 2 is inside the loop, and the outer layer of cloth 1 is outside the loop. The outer layer of cloth 1 has a filling area 12 and a connecting belt 11 surrounding the filling area 12 on the outward side.

[0085] As you can see, the fabric off the machine is a seamless cylinder with a filling effect, allowing for direct washing of the blanks. The filling yarn is protected between the outer and inner layers of fabric, eliminating the risk of loose threads being snagged during subsequent washing and drying. Furthermore, the blanks off the machine can be used directly as the main body of a jacket, with sleeves attached to complete the garment, significantly reducing the number of subsequent garment-making steps.

[0086] Preferably, the filling yarn, the face yarn and the bottom yarn meet at least one of the following requirements:

[0087] A. The filling yarn has stronger elasticity than the base yarn and the face yarn. For example, the filling yarn is a stretch yarn, and the face yarn and the base yarn are non-stretch yarns; or for another example, all three yarns are stretch yarns, and the filling yarn has the strongest elasticity.

[0088] B. After the filling yarn, face yarn, and backing yarn undergo the same heat treatment, the filling yarn will shrink more than the face yarn and backing yarn. For example, if the face yarn and backing yarn are both cotton, and the filling yarn is a synthetic fiber that shrinks when heated, the filling area will not bulge when it is first woven. After the fabric is unwoven, it needs to be washed, which includes a drying process. The filling yarn shrinks when heated, so the filling area will bulge only after washing.

[0089] C. After the filling yarn, face yarn, and base yarn are treated with the same solution, the filling yarn will shrink more than the face yarn and base yarn. For example, if the face yarn and base yarn are made of alkali-resistant fibers, and the filling yarn is made of less alkali-resistant fibers (such as cotton yarn), and the fabric is treated with alkali solution after it comes off the machine, the filling yarn will shrink, while the face yarn and base yarn will not shrink, and will only bulge after the alkali solution treatment.

[0090] When the filling yarn has greater elasticity or shrinkage than the base yarn and face yarn, the shrinkage difference between the connecting band and the filling area will be enhanced, causing the filling area to bulge outward more, leaving more space for air to be trapped between the outer and inner layers, and achieving better warmth retention. Specific yarn configurations as examples can be:

[0091] Option 1: veil: 40S cotton yarn, bottom yarn: 20D spandex, filling yarn: 75D polyester filament.

[0092] Option 2: veil: 38S staple yarn, bottom yarn: 40D nylon, filling yarn: 100D polyester filament.

[0093] Option 3: veil: 32S staple yarn, bottom yarn: 30D nylon, filling yarn: 40S wool core-spun yarn.

[0094] In order to ensure the lightness of the fabric, there may be some requirements for the base yarn, face yarn and filling yarn.

[0095] For the face veil and ground yarn, the seamless circular knitting machine has a needle count of 28 or more, the face veil has a count of 26S or more, and the ground yarn has a denier of 10D-75D. Unlike down, which requires a dense surface to prevent down from escaping, the product woven using this method uses yarns of 26S or more for the face veil and 10D-75D for the ground yarn. This helps prevent the combined mass of the face veil and ground yarn from exceeding the overall mass of the fabric, making the fabric lighter and thinner. The face veil can be cotton, and the ground yarn can be spandex.

[0096] Filling yarn can be either a staple core-spun micro-elastic yarn or a bulked yarn, with hollow bulked yarn being preferred. Hollow bulked yarn has a low density, contributing to a lightweight fabric and its hollow structure, which helps retain warmth. Therefore, when used as a floating yarn between the outer and inner fabrics, hollow bulked yarn can better simulate the effect of down filling. Hollow bulked yarn also has elasticity, which can be leveraged to enhance the differential contraction between the connecting band and the filling area, causing the filling area to bulge outward more. This creates a larger space between the outer and inner fabrics for air retention, further enhancing the warmth.

[0097] Furthermore, the filling yarn should be more elastic than the base yarn and the face yarn, with an elongation of 1.2 to 2.5 times that of the higher elongation of the base yarn or the face yarn. The stronger the elasticity of the filling yarn, the greater the difference in shrinkage between the connecting band and the filling area. However, if the filling yarn is too elastic compared to the base yarn and the face yarn, excessive tension in the floating threads of the filling area can result, causing deformation and shrinkage, which in turn hinders the outward expansion of the filling area. Preferably, both the base yarn and the face yarn are non-stretch yarns, and the elongation of the filling yarn is 120% to 250%.

[0098] As for the filling yarn, further, the filling yarn is a fine denier yarn with a fineness of 1.0dpf-2.4dpf or an ultra-fine denier yarn with a fineness of 0.3dpf-1.0dpf. The shrinkage is enhanced after washing, so that the shrinkage difference between the filling area and the connecting belt of the fabric after washing is more obvious, and the filling area bulges more strongly. In this way, the fabric is not afraid of washing, but can obtain a better warming effect after washing.

[0099] By implementing various measures to expand the shrinkage difference between the filling area and the connecting band, the outer layer of fabric has a greater shrinkage than the inner layer of fabric. In some embodiments, the inner layer of fabric is woven with the same number of columns as the outer layer of fabric. When the yarn specifications used for the inner and outer fabrics are similar, the inner layer of fabric is woven with fewer rows than the outer layer of fabric. When the inner and outer layers of fabric are connected end to end to form a circular fabric blank, the smaller number of rows of the inner layer of fabric can ensure that the actual height of the inner layer of fabric is similar to that of the outer layer of fabric, so that the outward side of the circular fabric blank is entirely outer layer of fabric, and the inward side is entirely inner layer of fabric. When the inner layer of fabric is a plain weft fabric, the inward side entirely consisting of the inner layer of fabric provides a smooth inner surface, while the outward side entirely consisting of the outer layer of fabric provides a bulged structure and an appearance similar to that of conventional plush-filled garments.

[0100] The embodiment of the present application correspondingly provides an air-warming fabric, including an outer layer of cloth, which is a weft-knitted fabric including filling yarn, base yarn and face yarn, and the outer layer of cloth includes a filling area and a connecting belt surrounding the filling area; in the filling area, the face yarn and the base yarn are looped at the same time, and the filling yarn forms floating lines; the connecting belt includes a positioning point and a shortcoming, at the positioning point, the filling yarn and the base yarn are looped at the same time, and at the shortcoming, the filling yarn, the base yarn and the face yarn all form floating lines; all floating lines in the filling area and the connecting belt are located on the side of the outer layer of cloth facing the inner layer of cloth.

[0101] During application, the inner layer of fabric is placed over the back of the outer layer. The edges of the inner layer are connected and fixed to the edges of the outer layer. The filling yarn in the filling area replaces the additional down in general down-filled garments in the form of floating threads. The anchor points in the connecting belt secure the ends of the floating threads of the filling yarn in the filling area. The disadvantage is that it shrinks after leaving the machine, making the connecting belt shrink more than the filling area. The connecting belt surrounds the filling area. The difference in shrinkage causes the filling area to bulge, which can trap air. The floating threads of the filling yarn are located on the side of the outer layer facing the inner layer, that is, in the middle of the fabric, which can hinder air flow and achieve warmth. The filling yarn is connected to the outer layer, so the down will not run. The filling yarn is not exposed and there is no need to worry about it being snagged. Therefore, it is not afraid of washing. After washing and drying, the floating threads of the filling yarn easily and clearly unravel. This fabric already contains filling yarn after weaving, eliminating the need for later filling, which can greatly reduce the steps in the downstream garment making process.

[0102] For ease of manufacture, the air-warming fabric further comprises an inner layer of cloth, which is connected end to end with the outer layer of cloth, and all floating threads in the filling area and the connecting belt are located on the side of the outer layer of cloth facing the inner layer of cloth.

[0103] Preferably, each filling yarn loops at least once where it overlaps the connecting band; within a column, at least one dot exists within two adjacent rows of any given positioning point; and within a row, at least one dot exists within two adjacent columns of any given positioning point. This distribution ensures that the floating threads of the filling yarn in each filling area are fixed at the edge of the filling area, preventing them from becoming tangled after washing and drying. This distribution ensures that the shrinkage of the connecting band is significantly greater than that of the filling area. These two combined effects help the filling area of ​​the fabric naturally expand after washing and drying, restoring its warmth to its pre-washing level.

[0104] Furthermore, the height of the connecting band at its narrowest point is two to eight rows, or the width at its narrowest point is two to eight columns. The connecting band is used to separate the filling areas, and "the narrowest point of the connecting band" means that the distance between two adjacent filling areas is two to eight rows or two to eight columns. This allows the connecting band to meet the above-mentioned positioning point and point-saving distribution methods while also simulating a quilted effect in appearance.

[0105] The preferred requirements for the facing yarn, the bottom yarn and the filling yarn of the air-warming fabric provided in the present application may be the same as the requirements in the weaving method of the air-warming fabric, and have corresponding effects.

[0106] Example 1, the veil is 40S cotton yarn, the bottom yarn is 20D spandex, the filling yarn is 75D polyester filament, the bottom yarn specifications used in the inner and outer layers are the same, the veil specifications used are also the same, and the structure of the connecting belt is as follows: Figure 3 As shown, the minimum cycle structure of the outer layer is as follows Figure 4 As shown, the repeated Figure 4 After splicing Figure 5 As shown, the connecting belt is composed of 4 columns and 6 rows as a connecting unit. Each connecting unit includes 6 default points (the ground yarn, face yarn and filling yarn are not looped) and 18 positioning points (the ground yarn and filling yarn are looped at the same time). There is a row of positioning points between adjacent default points, and a column of positioning points between adjacent default points. 20 connecting units form a diamond-shaped surrounding filling area. Each filling area includes 984 needles, and each needle is used to loop the face yarn and the ground yarn at the same time. The fabric woven in this way is as follows: Figure 6 As shown, the inner side is as Figure 7 shown. Figure 7 The inner layer of the fabric is smooth, with creases formed by placement, and no blocky bulges like down jackets. Figure 6 The filling area of ​​the outer layer of the fabric bulges outward, and the connecting belt has a quilted appearance. After washing, the fabric thickness is measured to be 7mm and the cubic decimeter weight is 82.4g / dm³.

[0107] Example 1

[0108] The face yarn is 38S spun yarn, the base yarn is 40D nylon, and the filling yarn is 100D polyester filament. When weaving the inner layer, the face and base yarns are woven together in a 2×1 right-hand twill. When weaving the outer layer, the face and base yarns are woven together in a 2×1 right-hand twill, with the filling yarn not being woven. The connecting band is composed of multiple continuous connecting units, each consisting of 4 columns by 8 rows, woven in a 3×1 right-hand twill, with the face yarn not being woven. After washing, the fabric measured 7mm thick and weighed 91.2g / dm³.

[0109] Example 2

[0110] The face yarn is 32S spun yarn, the base yarn is 30D nylon, and the filling yarn is 40S wool core-spun yarn. When knitting the inner layer, the face and base yarns are co-woven in a 1×1 staggered false rib pattern. When knitting the outer layer, the face and base yarns are co-woven in a 1×1 staggered false rib pattern in the filling area, with the filling yarn not woven in. The connecting band is composed of multiple continuous connecting units, each consisting of two columns by two rows, woven in a complementary checkerboard pattern, with the face yarn not woven in. After washing, the fabric measured a thickness of 7mm and a grammage of 99.5g / dm³. According to GB T 11048-2008, Test Method for Thermal Insulation of Textiles, the thermal insulation rate was 32.1%, comparable to that of ordinary down-filled cotton clothing.

[0111] The knitted fabric with a general thickness of 1mm has a gram per cubic meter weight of about 400g / dm³.

[0112] The filling yarn in the embodiment of the present application is occasionally looped at the connecting belt to achieve fixation. The connecting belt has parts where the three yarns do not form loops, and parts where the filling yarn and the bottom yarn are looped at the same time, so that the shrinkage degree of the connecting belt is stronger than that of the filling area. The connecting belt is subject to a larger constraint force to form a quilting effect. The filling area is less constrained and is surrounded by the connecting belt with a larger constraint. At the same time, when the filling yarn exists in the filling area in the form of floating lines, the shrinkage after the washing treatment causes the adjacent connecting belts to be close to each other due to the contraction force of the filling yarn, so that the filling area bulges outward, leaving a space between the outer cloth and the inner cloth to retain air. The floating lines of the filling yarn in the filling area inhibit the air flow between the outer cloth and the inner cloth, thereby achieving warmth retention.

[0113] The embodiment of the present application makes the fabric bulge through the organizational structure and the elasticity of the yarn, leaving enough space to store air, and uses filling yarn connected to the fabric to replace the filling material of conventional plush clothing. In addition to having the warmth-keeping ability of plush clothing, it does not lose down and can be machine washed, which simplifies the clothing manufacturing process for downstream garment factories.

[0114] Throughout this specification, references to terms such as "one embodiment," "certain embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" indicate that a specific feature, structure, material, or characteristic described in conjunction with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative uses of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0115] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A weaving method for air-warming fabric, characterized in that: Applicable to seamless circular knitting machines, the steps include: weaving the outer layer of fabric; When weaving the outer layer cloth, filling yarn, face yarn and bottom yarn are used. The outer layer cloth includes a filling area and a connecting belt surrounding the filling area. When weaving the filling area, the bottom yarn and the face yarn are woven into a surface layer. The filling yarn forms a floating thread on the back of the surface layer. The end point of the filling yarn serving as the floating thread is fixed to the connecting belt. When weaving the connecting tape, at some positions, the filling yarn and the bottom yarn are looped simultaneously, and the face yarn is a floating yarn to form a positioning point. At other positions, the filling yarn, the bottom yarn, and the face yarn are all floating yarns to form a missing point. There is at least one positioning point on any row of the connecting tape to fix the end point of the filling yarn. The step of weaving the outer layer cloth comprises: Weave the inner and outer layers of fabric connected top to bottom, align the floating yarn of the filling yarn with the inner fabric, and connect the inner and outer fabrics end to end.

2. The weaving method of the air-warming fabric according to claim 1, characterized in that: The filling yarn, face yarn and bottom yarn meet at least one of the following requirements: A. The elasticity of the filling yarn is stronger than that of the base yarn and the face yarn; B. After the filling yarn, face yarn and bottom yarn are subjected to the same heating treatment, the shrinkage of the filling yarn is stronger than that of the face yarn and the bottom yarn; C. After the filling yarn, face yarn and bottom yarn are treated with the same solution, the shrinkage of the filling yarn will be stronger than that of the face yarn and the bottom yarn.

3. The weaving method of the air-warming fabric according to claim 2, characterized in that: The elongation of the filling yarn is 1.2 to 2.5 times that of the base yarn or the face yarn, whichever has a higher elongation.

4. The weaving method of the air-warming fabric according to claim 2, characterized in that: The filling yarn is a fine denier yarn with a fineness of 1.0dpf-2.4dpf or an ultra-fine denier yarn with a fineness of 0.3dpf-1.0dpf. The count of the face yarn is above 26S, and the denier of the bottom yarn is 10D-75D.

5. The weaving method of the air-warming fabric according to claim 1, characterized in that: The filling yarn is a hollow bulked yarn.

6. The weaving method of the air-warming fabric according to claim 1, characterized in that: The steps of weaving an inner layer of cloth and an outer layer of cloth connected to each other, aligning the floating yarn of the filling yarn with the inner layer of cloth, and connecting the inner layer of cloth and the outer layer of cloth end to end include: The lower needle of the seamless circular knitting machine starts knitting, and after knitting a starting section with a first number of rows using the bottom yarn and the top yarn, the upper needle and the lower needle of the seamless circular knitting machine simultaneously hook a row of yarn, and then the upper needle keeps holding the loop, while the lower needle continues knitting; Then the stitch held by the upper needle is transferred to the lower needle, and the lower needle knits an end section with a second number of rows using the ground yarn and the top yarn; The continuing knitting of the lower needle includes: knitting the outer layer of cloth first and then knitting the inner layer of cloth, or knitting the inner layer of cloth first and then knitting the outer layer of cloth.

7. An air-warming fabric, characterized in that: The outer layer comprises an outer fabric, the outer layer being a weft-knitted fabric including a filling yarn, a ground yarn, and a face yarn, the outer layer comprising a filling area and a connecting belt surrounding the filling area, the filling area comprising a face layer, and floating yarns formed by the filling yarns being arranged across the back of the face layer, the endpoints of each floating yarn formed by the filling yarns in the filling area being fixed to the connecting belt; The connecting belt includes a positioning point and a ditch. At the positioning point, the filling yarn and the base yarn are looped simultaneously. At the ditch, the filling yarn, the base yarn and the face yarn all form floating yarns. There is at least one positioning point on any row of the connecting belt to fix the end point of the filling yarn. The air-warming fabric further comprises an inner layer of cloth, which is connected end to end with the outer layer of cloth. All the floating threads in the filling area and the connecting belt are located on the side of the outer layer of cloth facing the inner layer of cloth.

8. The air-warming fabric according to claim 7, characterized in that: The filling yarn, face yarn and bottom yarn meet at least one of the following requirements: A. The elasticity of the filling yarn is stronger than that of the base yarn and the face yarn; B. After the filling yarn, face yarn and bottom yarn are subjected to the same heating treatment, the shrinkage of the filling yarn is stronger than that of the face yarn and the bottom yarn; C. After the filling yarn, face yarn and bottom yarn are treated with the same solution, the shrinkage of the filling yarn will be stronger than that of the face yarn and the bottom yarn.

9. The air-warming fabric according to claim 8, characterized in that: The elongation of the filling yarn is 1.2 to 2.5 times that of the base yarn or the face yarn, whichever has a higher elongation.

10. The air-warming fabric according to claim 8, characterized in that: The filling yarn is a fine denier yarn with a fineness of 1.0dpf-2.4dpf or an ultra-fine denier yarn with a fineness of 0.3dpf-1.0dpf. The count of the face yarn is above 26S, and the denier of the bottom yarn is 10D-75D.

11. An air-warming garment, characterized in that: Contains the air-warming fabric according to any one of claims 7 to 10.

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