A weaving method of double-sided digital jacquard fabric

Abstract

The application provides a weaving method of double-sided digital jacquard fabric, and belongs to the technical field of fabric manufacturing method characterized by specific setting of warp and weft yarns. Two patterns Img_A and Img_B on the front and back sides are respectively designed, the images are corrected and deformed, and the new combined pattern G_AB is obtained after gray scale grouping and combination. After the front basic weave W_A is determined, the back basic weave W_B is obtained by mirroring W_A along the weave cycle boundary. The front weave library and the back weave library are generated, and then the surface weave and the inner layer weave of the double-layer weave are obtained. The appropriate surface warp density and surface weft density are set for weaving. The above scheme overcomes the problem that the front and back patterns and weaves of the double-sided jacquard fabric are limited, realizes the rapid processing of the double-sided digital image weave process, and makes the front and back sides of the fabric have different pattern styles. The fabric can be used to make integrated bags, bags, clothing fabric, decorative fabric and the like.

Description

TECHNICAL FIELD

[0001] The application relates to a weaving method of double-sided digital jacquard fabric, and belongs to the technical field of fabric manufacturing methods characterized by specific arrangement of warp and weft yarns. BACKGROUND

[0002] Double-sided fabric refers to interlaced fabric with independent weave effects on the front and back sides and without distinction between the front and back sides. Currently, the existing methods for forming double-sided effects of jacquard fabric include the following: one is to generate pattern plate files for the front and back sides respectively, and then to combine and design the two pattern plate files in the pattern weaving software, which may cause defects such as mismatching of organizations and missing of the bottom on the front and back sides; one is to overlap the front and back side patterns to generate a pattern with a transparent overlapping effect, and then to perform a pattern weaving process, such as CN101457433A which uses the superposition function in the pattern weaving CAD to superimpose different patterns on the front and back sides into a single layer pattern effect, and then adds organizations to each superimposed layer. This scheme has a complex processing procedure and a long processing time in the pattern weaving process; and the fabric developed by this patent has limitations in pattern and organization selection, and can only weave flat block-like patterns, and cannot weave digital patterns with complex patterns and more levels. Another scheme such as CN115341323A is essentially a single layer jacquard fabric, which forms the same or partially same patterns on the front and back sides by designing organizations on different patterns of the single layer fabric in cooperation with printing on the front and back sides. SUMMARY

[0003] Therefore, the application provides a weaving method of double-sided digital jacquard fabric, which can automatically complete the pattern weaving process, has a faster processing procedure, and can develop more complex digital patterns, and the front and back sides can exhibit different pattern effects by using different organization structures, so that the finished fabric has completely different pattern effects on the front and back sides without using printing technology.

[0004] Specifically, the application is implemented by the following scheme:

[0005] A weaving method of double-sided digital jacquard fabric includes the following steps:

[0006] (1) Digital pattern processing

[0007] Design two patterns Img_A and Img_B for the front and back sides respectively, and the two patterns are true color patterns or grayscale patterns, and the sizes are required to be the same.

[0008] Since the fabric is woven in the reverse direction, the image needs to be corrected and deformed, the front pattern Img_A is processed by reversing up, down, left and right, and the back pattern Img_B is processed by reversing up and down.

[0009] The gray scale values of each pixel in the two patterns Img_A and Img_B are extracted, and each gray scale value is grouped and merged. After the gray scale grouping and merging, new front pattern G_A and back pattern G_B are generated, and the relationship between each pixel of the new pattern and the original pattern satisfies:

[0010] G_A(i,j) = round(Img_A(i,j) / (255 / n A ))

[0011] G_B(i,j) = round(Img_B(i,j) / (255 / n B ))

[0012] In the formula, n A , n B represent the set gray scale number; when the base organizations W_A and W_B have circulation numbers of m A and m B respectively, then n A = m A -1 and n B = m B -1; round is a function of rounding the specified decimal.

[0013] After the gray scale grouping, new front and back patterns G_A and G_B are generated, and each row of pixels of the front and back patterns G_A and G_B is extracted. The rows of pixels of G_A and G_B are alternately inserted in the order from top to bottom in a 1:1 manner to generate a new synthetic pattern G_AB.

[0014] (2) Front and back organization design

[0015] First, the front base organization W_A is selected. The W_A organization can be selected as a single warp organization point twill or satin.

[0016] After W_A is determined, the design method of the back base organization W_B is as follows: generate an organization identical to W_A, and then mirror W_A along the organization circulation boundary line to obtain the back base organization W_B.

[0017] The characteristics of the front base organization W_A and the back base organization W_B are that they can be mirror image organizations, the organization structures are the same but the surface appearance line directions are opposite.

[0018] The single organization point in W_A organization is increased by one continuous organization point along the warp or weft direction, and a total of n A = m A -1 organizations are obtained to generate the front organization library W_A i (i = 1, 2, 3…n A ).

[0019] The total number of n is obtained by adding one by one the continuous points in the warp or weft direction of a single point in the W_B organization B = m B -1 organization, generate the reverse side organization library W_B i (i = 1, 2, 3…n B ).

[0020] Take each organization in the front organization library W_A i (i = 1, 2, 3…n A ), process it into the surface layer organization Wsur_A i (i = 1, 2, 3…n A ) of double-layer organization, the method is to insert a column of empty column on the right side of each column in the organization chart, representing the intersection of surface weft and inner warp, surface weft lifting inner warp sinking.

[0021] Take each organization in the reverse side organization library W_B i (i = 1, 2, 3…n B ), process it into the inner layer organization Winn_B i (i = 1, 2, 3…n B ) of double-layer organization, the method is to insert a column of full organization point column on the left side of each column in the organization chart, representing the intersection of inner weft and surface warp, surface warp lifting inner weft sinking.

[0022] (3) Weaving

[0023] According to the above pattern processing and organization design scheme, continue to fill in the pattern weaving process information in the jacquard design CAD software.

[0024] The double-sided jacquard fabric based on the present technology should be woven with double warp beam, warp yarn 1:1 configuration, weft yarn 1:1 configuration; Set appropriate surface warp density, surface weft density.

[0025] In the organization table of the pattern weaving process, the pattern G_AB synthesized in the digital pattern processing is laid out into the organization in the surface and inner layer organization library in a one-to-one correspondence. The technical method is: each pixel of the front pattern in G_AB is laid out with the organization in the surface layer organization library Wsur_A i (i = 1, 2, 3…n A ), the transition from black to white in the pixel is replaced one by one with the weft to warp organization in the surface layer organization library; each pixel of the reverse side pattern in G_AB is laid out with the organization in the inner layer organization library Winn_B i (i = 1, 2, 3…n B ), the transition from white to black in the pixel is replaced one by one with the weft to warp organization in the inner layer organization library.

[0026] After generating the pattern information, the double-jacquard electronic jacquard machine is used to weave the fabric, and a jacquard fabric with different patterns on two sides is produced.

[0027] In the above scheme, when designing and weaving, first, two patterns Img_A and Img_B on the front and back sides are designed respectively, the images are corrected and deformed, and after gray scale grouping and merging, a new synthetic pattern G_AB is generated. After determining the front basic weave W_A, the mirror image of W_A along the weave cycle boundary is obtained to get the back basic weave W_B. Then, the front weave library and the back weave library are generated, and the surface weave and the inner weave of the double-layer weave are obtained. The appropriate surface warp density and surface weft density are set for weaving. The problem of limited selection of patterns and weaves on the front and back sides of the double-sided jacquard fabric is overcome, the rapid processing of the double-sided digital image pattern weaving process is realized, and the fabric has different patterns on two sides, which can be used to make integrated bags, bags, clothing fabrics, and decorative fabrics.

[0028] Further, as a preferred:

[0029] When selecting the front and back patterns, a long pattern can be divided into two parts, and the fabric can be cut from one end after being taken off the loom, thereby producing an ultra-wide digital jacquard fabric.

[0030] When selecting the front and back patterns, a two-part continuous pattern can be selected, so that the front and back of the fabric seamlessly connect, and an integrated barrel-shaped fabric is produced.

[0031] Based on the weaving of the double-sided jacquard fabric of the present technology, when the warp yarns are configured in a 1:1 ratio, the warp yarn colors can be the same or different. When the warp yarn colors are different, a jacquard fabric with different colors on two sides can be produced. When the weft yarns are configured in a 1:1 ratio, the weft yarn colors can be the same or different. When the weft yarn colors are different, a jacquard fabric with different colors on two sides can be produced.

[0032] When selecting the front basic weave W_A and the back basic weave W_B, the weave cycle numbers can not be the same, and the weaves can not be mirror images of each other.

[0033] By using the above technical means, a jacquard fabric with different digital pattern styles on two sides can be developed, the fabric structure adopts two groups of warp yarns and two groups of weft yarns, and the design process flow is simple. Under the optimization of the technical scheme of the present application, the basic organization of the front and back sides does not need to have the same number of organization cycles, and can also not need to be mirror image organizations, thereby overcoming the problem that the selection of the front and back side organizations of the double-sided jacquard fabric is limited; when selecting the front and back side patterns, a long-width pattern can be divided into two, and the fabric is cut from one end after being taken off the loom, so as to produce an ultra-wide digital jacquard fabric; when selecting the front and back side patterns, two continuous patterns can be selected, so that the front and back sides of the fabric seamlessly connect, and a one-piece barrel-shaped fabric is produced; when the warp yarn color is different and / or the weft yarn color is different, a jacquard fabric with different colors on two sides is produced. When the warp yarn color is the same and the weft yarn color is the same, a jacquard fabric with the same color on two sides is produced. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 is two digital patterns Img_A1, Img_B1, which are respectively used as the front side (A1) and the back side (B1) of the fabric;

[0035] Figure 2 is a new synthetic pattern G_AB1 generated by digital pattern processing;

[0036] Figure 3 is a front side basic organization W_A1, 8-end 3-fly sate weave;

[0037] Figure 4 is a back side basic organization W_B1, which is a mirror image organization of W_A1 along the organization cycle boundary;

[0038] Figure 5 is a front side organization library W_A 1i (i=1, 2, 3…7);

[0039] Figure 6 is a surface layer organization library Wsur_A 1i (i=1, 2, 3…7);

[0040] Figure 7 is a back side organization library W_B 1i (i=1, 2, 3…7);

[0041] Figure 8 is an inner layer organization library Winn_B 1i (i=1, 2, 3…7);

[0042] Figure 9 is a partial effect picture of the finished double-sided fabric;

[0043] Figure 10The two designed digital patterns, Img_A2 and Img_B2, are used as the front (A2) and back (B2) of the fabric, respectively.

[0044] Figure 11 It is a new composite pattern G_AB2 generated after digital pattern processing;

[0045] Figure 12 It is a basic weave structure W_A2 on the front, with 8 roundels and 3-fly satin weave;

[0046] Figure 13 It is the reverse basic structure W_B2, a 5-end 3-fly satin weave;

[0047] Figure 14 It is the negative organization library W_B 2i (i = 1, 2, 3, 4);

[0048] Figure 15 It is the inner organization library Winn_B 2i (i = 1, 2, 3, 4);

[0049] Figure 16 This is a partial view of the finished double-sided fabric. Detailed Implementation

[0050] Example 1

[0051] This embodiment uses an 8-round 3-fly satin weave as the front base structure W_A1, and the reverse base structure W_B1 adopts a mirror weave with the same number of repeats as W_A1. The implementation method of this invention is described in detail.

[0052] (1) Digital pattern processing

[0053] Figure 1 In accordance with technical requirements, two digital patterns, Img_A1 and Img_B1, were designed to represent the front side of the fabric. Figure 1 A) and the reverse side ( Figure 1 B), both patterns have a pixel size of 2362×1181.

[0054] Deformation corrections were performed on patterns Img_A1 and Img_B1. Firstly, due to the W_A1 tissue cycle m... A1 =8, correct the pixel size distortion of patterns Img_A1 and Img_B1 to 2368×1184; then perform vertical and horizontal transformation on pattern Img_A1 and vertical transformation on pattern Img_B1.

[0055] Extract the grayscale value of each pixel in patterns Img_A1 and Img_B1, ranging from 0 to 255; grayscale level n. A1

[0056] =nB1 = m A1 -1 = m B1 -1 = 7; Group merge for each pixel according to the following formula, generate new pattern G_A1, G_B1:

[0057] G_A1(i,j) = round(Img_A1(i,j) / (255 / 7))

[0058] G_B1(i,j) = round(Img_B1(i,j) / (255 / 7))

[0059] Figure 2 In which the new synthetic pattern G_AB1 is generated. The method is to interpenetrate each row of pixels of the new pattern G_A1, G_B1 in the order from top to bottom 1:1.

[0060] (2) Front and back design

[0061] Figure 3 In which the 8 3 fly satin weave is selected as the front base weave W_A1.

[0062] Figure 4 In which the back base weave W_B1 is designed. The method is to mirror the front base weave W_A1 along the weave cycle boundary to generate 8 3 fly satin weaves. The surface pattern direction is opposite to W_A1 in appearance.

[0063] Figure 5 In which the front weave library W_A 1i (i = 1, 2, 3…7) is designed. The method is to design a group of gradient shadow weaves based on the front base weave W_A1, and the single weave point in the weave is increased by one weave point along the weft direction successively, and a total of n A1 = 7 weaves are obtained.

[0064] Figure 6 In which the surface weave library Wsur_A 1i (i = 1, 2, 3…7) is designed. The method is to take each weave in the front weave library W_A 1i (i = 1, 2, 3…7), insert a column of empty columns on the right side of each column in the weave chart, representing the intersection of surface weft and inner warp, the surface weft is raised and the inner warp is lowered, becoming the surface weave of double-layer weave.

[0065] Figure 7 In which the back weave library W_B 1i (i = 1, 2, 3…7) is designed. The method is to design a group of gradient shadow weaves based on the back base weave W_B1, and the single weave point in the weave is increased by one weave point along the weft direction successively, and a total of n B1 = 7 weaves are obtained.

[0066] Figure 8 Winn_B i (i = 1, 2, 3…7) in the reverse side fabric library W_B 1i (i = 1, 2, 3…7) in the reverse side fabric library W_B

[0067] (3) Weaving

[0068] The pattern G_AB1 is laid out in the digital pattern processing. The method is that each pixel of the front side pattern in G_AB1 is laid out with the fabric in the surface fabric library Wsur_A 1i (i = 1, 2, 3…7) in the reverse side fabric library W_B 1i (i = 1, 2, 3…7) in the reverse side fabric library W_B

[0069] The warp yarns in this embodiment are configured 1:1, and the warp yarn material is white polyester yarn; the weft yarns are configured 1:1, and the weft yarn material is black and gold polyester yarn; the set surface warp density is 30 roots / cm, and the surface weft density is 30 roots / cm, and the fabric is woven on an electronic jacquard machine to produce a large jacquard fabric with different patterns on two sides. The local effect of the fabric is shown in Figure 9 .

[0070] Embodiment 2

[0071] This embodiment uses 8 pieces of 3-fly satin weave as the front side basic fabric W_A2, and 5 pieces of 3-fly satin weave as the reverse side basic fabric W_B2, and the implementation method of the invention is described in detail.

[0072] (1) Digital pattern processing

[0073] Figure 10 In the digital pattern processing, two digital patterns Img_A2 and Img_B2 are designed according to technical requirements, and the two patterns are a picture pattern divided in the middle, which are respectively used as the front side (A) and the reverse side (B) of the fabric. The pixel size of the two patterns is 2362×1181, Figure 10 A) and the reverse side (B) of the fabric. The pixel size of the two patterns is 2362×1181, Figure 10 B), and the pixel size of the two patterns is 2362×1181,

[0074] The patterns Img_A2 and Img_B2 are deformed and corrected. First, since the fabric W_A2 has a cycle m A2 = 8, and the fabric W_B2 has a cycle m B2= 5, so the pixel size of the patterns Img_A2 and Img_B2 is first deformed to 2360 x 1200, then the pattern Img_A2 is processed by up-down and left-right transformation, and the pattern Img_B2 is processed by up-down transformation.

[0075] The gray scale value of each pixel of the patterns Img_A2 and Img_B2 is extracted, ranging from 0 to 255; the gray scale layer number n A2

[0076] = m A2 -1 = 7, n B2 = m B2 -1 = 4; each pixel value is grouped and merged according to the following formula to generate new patterns G_A2 and G_B2:

[0077] G_A2(i, j) = round(Img_A2(i, j) / (255 / 7))

[0078] G_B2(i, j) = round(Img_B2(i, j) / (255 / 4))

[0079] Figure 11 A new synthetic pattern G_AB2 is generated. The method is to interpenetrate each row of pixels of the new patterns G_A2 and G_B2 in the order of 1:1 from top to bottom.

[0080] (2) Front and back weave design

[0081] Figure 12 In the process, 8 pieces of 3 fly satin weave are selected as the front base weave W_A2.

[0082] Figure 13 In the process, 5 pieces of 3 fly satin weave are selected as the back base weave W_B2, so that the surface pattern direction is opposite to W_A2 in appearance.

[0083] Figure 5 In the process, the front weave library W_A 2i (i = 1, 2, 3…7) is designed. The method is to design a group of gradient shadow weave based on the front base weave W_A2, and the single weave point in the weave is increased by one weave point along the weft direction successively, and a total of n A2 = 7 weaves are obtained.

[0084] Figure 6 In the process, the surface weave library Wsur_A 2i (i = 1, 2, 3…7) is designed. The method is to take each weave in the front weave library W_A 2i (i = 1, 2, 3…7), and insert an empty column on the right side of each column in the weave diagram, representing the intersection of the surface weft and the inner warp, the surface weft lifting and the inner warp sinking, becoming the surface weave of the double-layer weave.

[0085] Figure 14 The back surface fabric library W_B 2i (i=1, 2, 3, 4) is designed based on the back surface fabric W_B2, and each single fabric point in the fabric is increased by one fabric point along the weft direction successively, and n B2 =4 fabrics are obtained in total.

[0086] Figure 15 The inner layer fabric library Winn_B 2i (i=1, 2, 3, 4) is designed based on the back surface fabric library W_B 2i (i=1, 2, 3, 4), and one full fabric point column is inserted at the left side of each column in the fabric diagram, representing the intersection of the inner weft and the surface warp, and the surface warp lifting the inner weft sinking to become the inner layer fabric of the double layer fabric.

[0087] (3) Weaving

[0088] The fabric is laid in the synthesized pattern G_AB2 in the digital pattern processing. The method is that each pixel of the front surface pattern in G_AB2 is laid with the fabric in the surface fabric library Wsur_A 2i (i=1, 2, 3…7), and the transition from black to white in the pixel is replaced one by one with the weft surface to warp surface fabric in the surface fabric library; and each pixel of the back surface pattern in G_AB2 is laid with the fabric in the inner layer fabric library Winn_B 2i (i=1, 2, 3, 4), and the transition from white to black in the pixel is replaced one by one with the weft surface to warp surface fabric in the inner layer fabric library.

[0089] In this embodiment, the warp yarns are configured in 1:1, and the warp yarn raw material is white polyester yarn; the weft yarns are configured in 1:1, and the weft yarn raw material is black polyester yarn; the surface warp density is set to 30 roots / cm, and the surface weft density is set to 30 roots / cm, and the whole length of the character width pattern is produced by reverse weaving on the electronic jacquard machine, but the barrel-shaped jacquard fabric connected at the beginning and the end. The local effect of the fabric is shown in Figure 16 .

Claims

1. A method for weaving a double-sided digital jacquard fabric, characterized in that, Includes the following steps: Step 1: Digital Pattern Processing S1. Design a front pattern Img_A and a back pattern Img_B. Both patterns should be either true-color or grayscale images and be the same size. S2, the front pattern Img_A is flipped vertically and horizontally, while the back pattern Img_B is flipped vertically. S3, extract the grayscale value of each pixel in the front pattern Img_A and the back pattern Img_B, group and merge each grayscale value, and generate new front pattern G_A and back pattern G_B after grayscale grouping and merging. The relationship between each pixel of the new image and the original image satisfies: G_A(i,j)=round(Img_A(i,j) / (255 / n A )), G_B(i,j)=round(Img_B(i,j) / (255 / n B )), In the formula, n A n B This indicates the set number of gray levels; the cycle numbers for the positive base organization W_A and the negative base organization W_B are m respectively. A m B n A =m A -1, n B =m B -1; `round` is a function that performs rounding operations on a specified decimal number. S4, extract each row of pixels from the front pattern G_A and the back pattern G_B, and interleave each row of pixels from the front pattern G_A and the back pattern G_B in a 1:1 ratio from top to bottom to generate a new composite pattern G_AB. Step 2, Front and Back Organization Design S1, select a twill or satin weave with W_A as the basic weave point on the front side. S2: First, generate a structure identical to the front base structure W_A. Then, mirror the front base structure W_A along the boundary line of the structure cycle to obtain the reverse base structure W_B. The front base structure W_A and the reverse base structure W_B are mirror images of each other, with the same structure but opposite surface texture directions. S3, for each individual weave point in the frontal base weave W_A, successively add consecutive weave points along the warp or weft direction, resulting in a total of n. A =m A -1 organization, generating a positive organization library W_A i (i = 1, 2, 3…n) A ), By successively adding consecutive weft points along the warp or weft direction to a single weft point in the base weave W_B on the reverse side, a total of n is obtained. B =m B -1 organization, generating the negative organization library W_B i (i = 1, 2, 3…n) B ), The positive organization library W_A i (i = 1, 2, 3…n) A Each tissue in the process is treated as the surface tissue Wsur_A of a two-layered tissue. i (i = 1, 2, 3…n) A The method is as follows: Insert an empty column to the right of each column in the organization chart, representing the intersection of the outer latitude and inner longitude, with the outer latitude rising and the inner longitude sinking. Retrieve the reverse organization library W_B i (i = 1, 2, 3…n) B Each organization in ) is processed as the inner organization Winn_B of a two-layer organization. i (i = 1, 2, 3…n) B The method is as follows: Insert a full-weave point column on the left side of each column in the weft chart, representing the intersection of the inner latitude and outer warp. The outer warp is raised and the inner latitude is lowered. Step 3, Weaving Based on the pattern processing in step one and the weaving design scheme in step two, continue to fill in the weaving process information in the jacquard design CAD software. In the weaving process structure table, the pattern G_AB synthesized in step one is used to lay down the color of each pixel in the surface and inner layer structure library in a one-to-one correspondence manner. The method is: each pixel of the front pattern in G_AB uses the surface structure library Wsur_A. i (i = 1, 2, 3…n) A In the organization layer of G_AB, the transition from black to white in each pixel corresponds one-to-one with the latitude-to-longitude organization in the surface organization library; each pixel of the reverse pattern in G_AB is replaced by the inner organization library Winn_B. i (i = 1, 2, 3…n) B In the fabric layout, the transition from white to black in the pixels corresponds one-to-one with the weft-to-warp structure in the inner layer structure library. After generating the pattern information, it is woven in reverse on a double warp beam electronic jacquard machine to produce jacquard fabrics with two different patterns on each side.

2. The weaving method of a double-sided digital jacquard fabric according to claim 1, characterized in that: It adopts double warp beam weaving, with a 1:1 warp yarn ratio and a 1:1 weft yarn ratio.

3. The weaving method of a double-sided digital jacquard fabric according to claim 2, characterized in that: The warp yarns are of different colors, and / or the weft yarns are of different colors, to produce jacquard fabrics with different colors on both sides.

4. The weaving method of a double-sided digital jacquard fabric according to claim 2, characterized in that: The warp yarns are of the same color, and the weft yarns are of the same color, producing a jacquard fabric with the same color on both sides.

5. A method for weaving a double-sided digital jacquard fabric according to any one of claims 1 to 4, characterized in that: In step one, the front pattern Img_A and the back pattern Img_B are formed by dividing a long pattern in two. After the greige fabric comes off the machine, it is cut from one end to produce an ultra-wide digital jacquard fabric.

6. A method for weaving a double-sided digital jacquard fabric according to any one of claims 1 to 4, characterized in that: In step one, the front pattern Img_A and the back pattern Img_B are two-way continuous patterns, and the front and back of the fabric are seamlessly connected to produce a one-piece barrel-shaped fabric.

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