A deformation-resistant sweater-like fabric and a method for making the same

Abstract

The application discloses an anti-deformation sweater-imitating style fabric and a manufacturing method thereof, and belongs to the field of textiles. First cyclic structures with a first row number are alternately knitted according to a longitudinal knitting direction. In the first cyclic structures, a first yarn is used to knit continuous areas and omitted areas which alternately appear in the transverse direction. In the continuous areas, all the loops of the first yarn in multiple columns are continuous. In the omitted areas, the first yarn alternately forms a floating part with a first column number and a loop part with a second column number in the transverse direction. In the longitudinal knitting direction, the upper and lower adjacent first cyclic structures are staggered, so that the floating parts in the adjacent first cyclic structures are not connected in the longitudinal direction. The shrinkage of the floating part causes the edge of the continuous area connected with the floating part to be concave on the process front surface, and the remaining positions to be convex, forming a coarse texture of the sweater imitation. Therefore, the appearance of the positive and negative needle sweaters knitted by low-gauge equipment can be imitated by using a high-gauge circular knitting machine, and the anti-deformation and comfortable hand feeling characteristics of high-gauge fabric are also achieved.

Description

Technical Field

[0001] This invention relates to a deformation-resistant, sweater-style fabric and its manufacturing method, belonging to the textile field. Background Technology

[0002] Commercially available sweaters are made using flat knitting machines, which typically have lower gauges. Currently, the highest gauge flat knitting machine used in actual production is 22 gauge. Higher gauge machines use finer yarns, resulting in coarser yarns used in commercially available sweaters. This produces a coarser texture, but the coarser yarn can also cause discomfort if it comes into direct contact with the skin without thermal underwear. Furthermore, the lower gauge of the flat knitting machine, which requires coarser yarns, makes the fabric more prone to deformation. A common consequence is that some sweaters stretch significantly after machine washing. Fabrics woven on high-gauge circular knitting machines are more resistant to deformation, but the texture is finer and lacks the clear definition of a sweater's texture. Currently, it is not possible to create a knitted fabric with the coarse texture of a sweater using circular knitting machines. Summary of the Invention

[0003] In order to overcome the shortcomings of the existing technology, the present invention provides a deformation-resistant imitation sweater style fabric and its manufacturing method, which can use high-gauge equipment to produce the fabric style of products from low-gauge equipment, thus solving the deformation problem and producing a clear texture.

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

[0005] In a first aspect, this application provides a method for manufacturing a deformation-resistant, sweater-style fabric, including a weaving process. The weaving process is applicable to a circular knitting machine, in which a first repeat structure with a first row number is alternately woven using a first yarn in a longitudinal weaving direction. In the first repeat structure, a continuous area and a dart area that alternately appear laterally are woven using the first yarn. In the continuous area, the first yarn in multiple consecutive columns are all looped. In the dart area, the first yarn alternately forms a float portion with a first column number and a looped portion with a second column number laterally. In the longitudinal weaving direction, adjacent first repeat structures are staggered so that the float portions in adjacent first repeat structures are not connected longitudinally.

[0006] The method for manufacturing the anti-deformation, sweater-style fabric provided in this application employs a partial "dangling needle" knitting technique. This involves holding some needles without forming loops, while other needles knit several rows before forming loops. During this holding period, the first newly introduced yarn passes through the holding needles to form a float, known as the float section. When re-forming loops, the loops of the previous row (in knitting order) cross the first row of floats before looping with the loops of the next row (in knitting order), causing longitudinal shrinkage of the fabric. The edges connecting the continuous area and the float section (specifically, the edges in the left-right direction), as well as the looped section, are stretched, bulging on the reverse side of the knitted fabric and correspondingly recessed on the front side. Meanwhile, the continuous area away from the float section bulges on the front side. The indentation on the front of the fabric creates the appearance of a reverse knit sweater, while the protrusion on the front creates the appearance of a regular knit sweater. Therefore, a high-gauge circular knitting machine can be used to imitate the appearance of a reverse knit sweater made by a low-gauge machine. At the same time, because the fabric is woven by a high-gauge circular knitting machine, it has strong resistance to deformation and can use finer yarns to make the fabric more comfortable when in contact with the skin.

[0007] Furthermore, the first yarn is a natural fiber or regenerated cellulose fiber that has undergone reduction dyeing; after the weaving process, a fading process is also included, which includes washing the fabric after the weaving process by at least one of general washing, rinsing, and enzyme washing, so as to locally fade the first yarn.

[0008] The continuous area, away from the floats, will be raised on the front of the process. During the fading process, the raised part will fade more easily than the rest, thus allowing different parts of the fabric to fade to different degrees, creating sweater-style products with a washed (antique / retro) look.

[0009] Furthermore, in the weaving process, after each weaving of the first yarn, a second yarn is inserted to form a padding structure, the diameter of the second yarn being smaller than the diameter of the first yarn. That is, a second yarn is additionally introduced into the first loop structure.

[0010] The padding structure refers to a structure formed by tufting and floats. The second yarn is woven by tufting and floats, while the first yarn is woven by loops plus floats. Therefore, the second yarn is located more on the reverse side of the process and is more likely to come into contact with the skin. The second yarn is finer than the first yarn, which prevents the second yarn from being exposed on the front side of the process.

[0011] Furthermore, the second yarn is made of synthetic fiber with a single filament fineness of less than 2.4 dpf. High F-number yarns can make the fabric feel more comfortable.

[0012] Furthermore, at least one loop of the first yarn exists between two adjacent loops in the same column to prevent the knitting needle from taking in too much yarn and increasing needle wear.

[0013] Furthermore, a stone mill washing process is included after the weaving process.

[0014] The second yarn has a single filament fineness of less than 2.4 dpf and low single filament strength. It is easily broken during the stone washing process. The broken part covers the fabric backing, making the fabric backing feel better and giving it a velvety texture.

[0015] Furthermore, on the same second yarn, there are 2 to 5 rows of floats between two adjacent loops.

[0016] If the float between two adjacent loops of the same second yarn is too short, the knitting needles will bite the yarn too densely, resulting in greater needle wear, and the yarn will not easily break during the stone washing process. If the float between two adjacent loops of the same second yarn is too long, the yarn will snag severely, and the yarn will easily break completely during the stone washing process, rather than partially, resulting in poor coverage of the fabric base.

[0017] Furthermore, the first row has 4 rows.

[0018] The more rows of stitches (the first row), the worse the feel of the fabric. However, the fewer rows of stitches, the weaker the texture. When there are 4 rows of stitches, you can create a textured surface without making the fabric too rough to the touch.

[0019] Furthermore, the first column has 1 to 2 columns, and the second column has 1 to 4 columns.

[0020] Non-circular columns (floating sections) have the greatest impact on nearby circular columns (edges or circular sections of continuous areas). The impact on circular columns decreases as they move further away from the floating sections. As the distance from the floating sections increases, circular columns change from concave to convex. The first column consists of 1 to 2 columns, and the second column consists of 1 to 4 columns, which ensures that the circular sections will always have a concave shape.

[0021] Ideally, both the first and second columns should be two columns to achieve an appearance that most closely resembles that of a sweater knitted by a flat knitting machine.

[0022] Secondly, this application provides a deformation-resistant, sweater-like fabric, made using the manufacturing method of the deformation-resistant, sweater-like fabric described in the first aspect. This fabric has a sweater-like appearance and a comfortable feel.

[0023] The beneficial effects of this invention are as follows: In certain locations, this invention causes a row of loops to cross over the first row of floats before looping with the next row, resulting in longitudinal shrinkage of the fabric. The edges connecting the continuous area and the floats, as well as the looping area, are stretched, causing a depression on the fabric's surface. Conversely, the continuous area away from the floats protrudes on the fabric's surface. The depression on the fabric's surface resembles a reverse knit sweater, while the protrusion resembles a regular knit sweater. Therefore, a high-gauge circular knitting machine can mimic the appearance of a reverse knit sweater woven on a low-gauge machine. Furthermore, because the fabric is woven on a high-gauge circular knitting machine, it has strong resistance to deformation and allows for the use of finer yarns, making the fabric more comfortable against the skin.

[0024] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings. Attached Figure Description

[0025] Figure 1 This is a weaving design diagram of a deformation-resistant, sweater-style fabric provided in Embodiment 1 of this application.

[0026] Figure 2 This is a weaving design diagram of a deformation-resistant, sweater-style fabric provided in Embodiment 2 of this application.

[0027] Figure 3 This is a weaving design diagram of a deformation-resistant, sweater-style fabric provided in Embodiment 3 of this application. Detailed Implementation

[0028] 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 denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0029] The following disclosure provides many different embodiments or examples for implementing different structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0030] In recent years, sweaters have become more than just warm clothing. Wide necklines and cropped designs have also been incorporated into sweaters. These fashionable styles are usually in direct contact with the skin, and wearing them over a T-shirt would look odd. However, sweaters are knitted on flat knitting machines, which have larger machine gauges, resulting in poor resistance to deformation and a rough feel.

[0031] To address the above problems, this application provides a method for manufacturing a deformation-resistant, sweater-style fabric, including a weaving process. The weaving process is applicable to circular knitting machines, especially seamless underwear machines. A first repeat structure with a first row number is alternately woven using first yarns in the longitudinal weaving direction. In the first repeat structure, continuous areas and dart areas that alternate laterally are woven using the first yarns. In the continuous areas, multiple rows of first yarns form loops, while in the dart areas, the first yarns alternately form float portions with a first row number and loop portions with a second row number. In the longitudinal weaving direction, adjacent first repeat structures are staggered so that the float portions in adjacent first repeat structures are not connected longitudinally.

[0032] This manufacturing method employs a partial "suspended needle" knitting technique, where some needles are held in place without forming loops. Loops are formed after the other needles have knitted several rows. During this period of holding without forming loops, the first newly introduced yarn passes through the held needles, forming a float, known as the float section. When re-forming loops, the loops of the previous row (in knitting sequence) cross over the first row's floats before looping with the loops of the next row (in knitting sequence). This causes longitudinal shrinkage of the fabric. The edges connecting the continuous area and the float section, as well as the looped area, are stretched, resulting in a bulge on the reverse side of the knitted fabric and a depression on the front side. Conversely, the continuous area away from the float section bulges on the front side. The depression on the front side resembles the appearance of a reverse knit sweater, while the bulge resembles the appearance of a knitted sweater. Therefore, a high-gauge circular knitting machine can mimic the appearance of a knitted / reverse knit sweater made on a low-gauge machine. Furthermore, because the fabric is knitted on a high-gauge circular knitting machine, it has strong resistance to deformation and allows for the use of finer yarns, making the fabric more comfortable against the skin.

[0033] The larger the number of stitches (first row), the worse the feel of the fabric. However, the smaller the number of stitches, the weaker the texture. The optimal first row is 4 rows, which can create a textured surface without making the fabric too rough to the touch.

[0034] The non-circular columns (floating sections) have the greatest impact on the nearby circular columns (edges or circular sections of the continuous area). The impact on the circular columns decreases as they are further away from the floating sections. As the distance from the floating sections increases, the circular columns change from concave to convex. Preferably, the first column has 1 to 2 columns and the second column has 1 to 4 columns, which ensures that the circular sections will always have a concave shape.

[0035] Example 1

[0036] Using an E28 seamless underwear machine to knit a one-piece garment in the style of a fine-knit (E12 or E14) sweater, the basic knit pattern of this embodiment is shown in the diagram below. Figure 1 As shown, rows 1 to 4 (or "roads") form the lower first repeating pattern, and rows 5 to 8 form the upper first repeating pattern, with a total of 4 rows in the first repeating pattern. Each first repeating pattern includes horizontally alternating continuous areas and dart areas woven using the first yarn. Figure 1 In the diagram, the top left 32 rows (4 rows, 8 columns) form the dart area in the first repeat weave above; the top right 32 rows (4 rows, 8 columns) form the continuous area in the first repeat weave above; the bottom left 32 rows (4 rows, 8 columns) form the continuous area in the first repeat weave below; and the bottom right 32 rows (4 rows, 8 columns) form the dart area in the first repeat weave below. Within the dart area, the first yarn alternately forms two rows of floats and two rows of loops laterally. For example, rows 5 to 8 in columns 13 and 14 form a float, and rows 1 to 4 in columns 3 and 4 form a loop. Adjacent first repeat weaves are staggered to ensure that the floats in adjacent first repeat weaves are not connected longitudinally. Figure 1 Each floating line section in the middle corresponds to a continuous area directly above and below it. For example... Figure 1 The knitting point in the 5th row of the 5th column actually crosses the floats of rows 1 to 4 in the 5th column, forming a loop with the yarn in the continuous area below row 1 (not shown in the diagram). This creates a longitudinal contraction, and the looped area is stretched, bulging on the back of the fabric and correspondingly causing the front of the fabric to concave. The further the looped column is from the floats, the smaller the effect; as the distance from the floats increases, the looped column changes from concave to convex. Figure 1 The floating line section consists of 2 columns × 4 rows. After removal from the machine, the impact range extends to approximately 3 columns. This causes rows 1 to 4 in columns 3, 4, 7, and 8 to be recessed on the front side of the process; rows 1 to 4 in column 9 to be recessed in the middle; rows 1 to 4 in column 10 to transition to a raised position; and rows 1 to 4 in columns 11 and 12 to be completely raised. Similarly, rows 5 to 8 in columns 16, 15, 12, 11, 8, and 7 are recessed; rows 5 to 8 in column 6 are partially recessed; rows 5 to 8 in column 5 to transition to a raised position; and rows 5 to 8 in columns 4 and 3 to be completely raised.

[0037] In this embodiment, the first yarn can be selected from indigo cotton yarn, sulfur black cotton yarn, washable colored cotton yarn, indigo Tencel, sulfur black Tencel, washable colored Tencel, indigo wool, sulfur black wool, washable colored wool, etc. A fading process is also included after the knitting process. The fading process includes washing the fabric after the knitting process using at least one of the following methods: general washing, bleaching, and enzyme washing, to locally fade the first yarn. The continuous area away from the float yarn will be raised on the process front. In the fading process, the raised part is more prone to fading than the rest, thus allowing for different degrees of fading in different parts of the fabric, creating a sweater-style product with a washed-out characteristic.

[0038] Example 2

[0039] The basic weaving design diagram of this embodiment is as follows: Figure 2 As shown, based on Example 1, a second yarn is inserted after each weaving of the first yarn to form a padding structure. Specifically, the yarn used in rows 1, 3, 5, 7, 9, 11, 13, and 15 is the first yarn, forming one first repeat structure; rows 9, 11, 13, and 15 form another first repeat structure; and the yarn used in rows 2, 4, 6, 8, 10, 12, 14, and 16 is the second yarn. The diameter of the second yarn is smaller than that of the first yarn. The padding structure refers to a structure formed by loops and floats. The weaving behavior of the second yarn is looping and floats, while the weaving behavior of the first yarn is looping plus floats. Therefore, the second yarn is more located on the reverse side of the fabric, making it easier to contact the skin. The second yarn is finer than the first yarn, which improves the feel of the fabric base.

[0040] Preferably, the second yarn is made of synthetic fiber with a single filament fineness below 2.4 dpf, which makes the fabric feel more comfortable. Although the second yarn is finer, excessive intake of the second yarn can increase wear on the knitting needles. Figure 2 In the illustrated embodiment, at least one loop of the first yarn exists between two adjacent loops in the same column to prevent the knitting needle from taking in too much yarn and increasing needle wear. In Embodiment 1, methods such as regular washing, rinsing, and enzyme washing are used for aging, while in Embodiment 2, stone washing can be used. On the one hand, the raised portion formed by the first yarn is more easily rubbed against the stones, resulting in different degrees of fading in different parts of the fabric. On the other hand, the stones will partially break the second yarn, and the broken portion covers the fabric backing, improving the fabric's feel. If the float between two adjacent loops of the same second yarn is too short, the knitting needle will take in too much yarn, resulting in greater needle wear, and it will not be easily broken during the stone washing process. If the float between two adjacent loops of the same second yarn is too long, it will cause severe snagging, and it will be easily completely broken during the stone washing process, rather than partially broken, resulting in poor coverage of the fabric backing. More preferably, in Figure 2 In the illustrated embodiment, there are 3 columns of floating lines between two adjacent loops, which effectively covers the fabric backing.

[0041] Example 3

[0042] The basic weaving design diagram of this embodiment is as follows: Figure 3 As shown, based on Embodiment 2, it is not required that the floating line portion in a first cycle must be aligned with the continuous area in the upper and lower first cycles, and the upper and lower opposite areas of each floating line portion do not necessarily have to be continuous areas. Figure 3In the illustrated embodiment, the float portion can be directly opposite the looping portion in the sparse area of ​​the adjacent first cycle, or it can be directly opposite the edge of the continuous area in the adjacent first cycle, which can knit more patterned imitation sweater products. Similarly, it can achieve the staggering of the upper and lower adjacent first cycle structures so that the float portions in the adjacent first cycle structures are not connected in the longitudinal direction. Similarly, it can achieve the pulling of the non-looping column (float portion) to the nearby looping column (edge ​​of the continuous area or looping portion) to form a depression, and the position away from the float portion transitions from depression to convexity.

[0043] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions 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 one or more embodiments or examples.

[0044] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A method for manufacturing a deformation-resistant, sweater-style fabric, comprising a weaving process, characterized in that, The weaving process is applicable to a circular knitting machine, in which a first repeat structure with a first number of rows is alternately woven using a first yarn in the longitudinal weaving direction; in the first repeat structure, the first yarn is used to weave horizontally alternating continuous areas and dart areas, in which the first yarn in the continuous area forms loops in multiple consecutive columns, and in the dart area, the first yarn alternately forms floating sections with a first number of columns and looped sections with a second number of columns in the transverse direction; in the longitudinal weaving direction, adjacent first repeat structures are staggered so that the floating sections in adjacent first repeat structures are not connected in the longitudinal direction.

2. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 1, characterized in that, The first yarn is a natural fiber or regenerated cellulose fiber that has undergone reduction dyeing; after the weaving process, a fading process is also included, which includes washing the fabric after the weaving process by at least one of general washing, rinsing, and enzyme washing, so as to locally fade the first yarn.

3. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 1, characterized in that, In the weaving process, after each weaving of the first yarn, a second yarn is inserted to form a padding structure, and the diameter of the second yarn is smaller than the diameter of the first yarn.

4. The method for manufacturing the anti-deformation imitation sweater style fabric according to claim 3, characterized in that, The second yarn is a chemical fiber with a single filament fineness of less than 2.4 dpf.

5. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 4, characterized in that, There must be at least one loop of the first yarn between two adjacent loops in the same column.

6. The method for manufacturing the anti-deformation imitation sweater style fabric according to claim 4, characterized in that, The process includes a stone mill washing step after the weaving process.

7. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 6, characterized in that, On the same second yarn, there are 2 to 5 rows of floats between two adjacent loops.

8. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 1, characterized in that, The first row has 4 rows.

9. The method for manufacturing the anti-deformation, sweater-style fabric according to claim 1, characterized in that, The first column has 1 to 2 columns, and the second column has 1 to 4 columns.

10. A deformation-resistant, sweater-style fabric, characterized in that, Made by the method of manufacturing the anti-deformation sweater-style fabric according to any one of claims 1 to 9.

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