A method for producing elastic partitioned knitted products

Abstract

This invention discloses a method for producing elastic zoned knitted products, relating to the field of double-needle-bed warp-knitted spacer fabrics. The method includes the following steps: Step 1, threading yarn onto the guide bars of a Jacquard knitting machine; Step 2, designing a Jacquard pattern and inputting the program into the control system of the Jacquard knitting machine; Step 3, the first and second ground guide bars knit on the front needle bed to form the upper surface, and the third and fourth ground guide bars knit on the rear needle bed to form the lower surface; different monofilaments are threaded into the first and second Jacquard guide bars respectively, and the compressive elastic zones with different shapes, sizes, and elasticities along the fabric weaving direction and fabric width direction are formed through the interaction of yarn type, Jacquard basic padding number, Jacquard offset signal, and the synchronization degree of Jacquard guide bar knitting. This invention utilizes the different offset signals of the Jacquard guide bars to produce zoned products of arbitrary shapes along the transverse or longitudinal direction, achieving shape innovation in zoned products.

Description

Technical Field

[0001] This invention relates to the field of double-needle bed warp-knitted spacer fabric technology, and in particular to a method for producing an elastic partitioned knitted product. Background Technology

[0002] 3D warp-knitted spacer fabric is a novel three-dimensional fabric. Due to its excellent water and air permeability, quick-drying after washing, and comfortable pressure relief, it has been widely used in recent years in fields such as home furnishings, automobiles, infant products, elderly care, and medical care. Traditional warp-knitted spacer fabrics maintain a consistent compressive elasticity throughout their width and weave length. In some applications, fabrics with varying compressive elasticities in different areas are required. The conventional approach was to cut fabrics with different compressive elasticities and then sew them together to create a composite with varying compressive elasticities. This method increases production steps, wastes manpower, reduces production efficiency, and increases product costs.

[0003] Existing patent applications "2019109018605 Compression Elastic Modulus Slit Warp-Knitted Spacer Fabric and Preparation Method Thereof" and "201921588983X A Compression Elastic Modulus Slit Warp-Knitted Spacer Fabric" mention compression elastic modulus slit warp-knitted spacer fabrics and their production methods. However, their production method uses a conventional double-needle bed warp knitting machine, relying solely on the type and method of yarn threading in the ground comb to achieve the purpose of elastic zoning. This method only allows for regular striped distribution in each area, making it impossible to produce arbitrarily shaped zoned products. Summary of the Invention

[0004] The purpose of this invention is to provide a method for producing elastic partitioned knitted products to solve the problems existing in the prior art. By utilizing different offset signals of Jacquard combs, partitioned products of arbitrary shapes along the horizontal or vertical direction can be made, thereby achieving shape innovation of partitioned products.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] This invention provides a method for producing an elastic partitioned knitted product, comprising the following steps:

[0007] Step 1: According to the design requirements, thread the yarn of the required specifications and type onto the guide bar of the Jacquard knitting machine;

[0008] Step two: Design the Jacquard pattern according to the flexible zoning requirements, and input the program into the control system of the Jacquard warp knitting machine. The specific program design belongs to the prior art, so this invention will not elaborate on it.

[0009] Step 3: The first and second ground combs knit together on the front needle bed to form the upper surface, while the third and fourth ground combs knit together on the rear needle bed to form the lower surface. The first Jacquard comb inserts monofilament X, and its basic Jacquard padding number is A. Different Jacquard offset signals are set in different elasticity zones, ultimately forming different offset padding numbers A1, A2, A3, and A4. The second Jacquard comb inserts monofilament Y, and its basic Jacquard padding number is D. The same or different Jacquard offset signals are set in different elasticity zones, ultimately forming offset padding numbers D1, D2, D3, and D4 in each zone. The first and second Jacquard combs work together through the yarn type, basic Jacquard padding number, Jacquard offset signal, and the synchronization of Jacquard comb knitting to form compression-resistant elastic zones with different shapes, sizes, and elasticities along the fabric weaving direction and fabric width direction.

[0010] The existing ground comb design requires different yarn threading settings based on the width of different zones, which is complex, time-consuming, and labor-intensive. This invention uses a Jacquard warp knitting machine with Jacquard guide bars. The Jacquard guide bars are fully threaded, and the offset of the Jacquard eliminates the need for different yarn threading settings. The design is simple, the process is concise, and it is easy for workers to operate. It saves yarn arrangement and threading time, improves production efficiency, and has wider applicability.

[0011] Optionally, the monofilament X and monofilament Y are monofilaments with different diameters, and the diameters of monofilament X and monofilament Y are both between 0.05-0.5 mm.

[0012] Optionally, the monofilament X and monofilament Y are monofilaments with different bending stiffnesses. The monofilament X and monofilament Y are both one of polyester monofilament, nylon monofilament, polypropylene monofilament, and modified polyester filament, or the monofilament X and monofilament Y are both core-sheath composite monofilaments composed of two of the following: polyester monofilament, nylon monofilament, polypropylene monofilament, and modified polyester filament.

[0013] Optionally, the basic Jacquard padding yarn code A of the first Jacquard comb is selected as 0-1-0-1 / 4-5-4-5 / / , and different Jacquard offset signals are set at different partition positions as follows: TTTT HHHH, HHHH HHHH, HHHH TTTT, HHTHHHTH. Finally, different offset padding yarn codes are formed for each elastic partition, which alternately form loops on the front and back needle beds: A1: 1-2-1-2 / 4-5-4-5 / / , A2: 0-1-0-1 / 4-5-4-5 / / , A3: 0-1-0-1 / 5-6-5-6 / / , and offset padding yarn code A4: 0-1-1-1 / 4-5-5-5 / / , which only forms loops on the front needle bed.

[0014] Optionally, the basic jacquard padding yarn code D of the second jacquard comb is selected as 1-0-1-0 / 5-4-5-4 / / , and different jacquard offset signals are set at different elastic zone positions as follows: TTTT HHHH, HHHH HHHH, HHHH TTTT, HTHH HTHH. Finally, different offset padding yarn codes are formed for each elastic zone, which alternately form loops on the front and back needle beds: D1: 2-1-2-1 / 5-4-5-4 / / , D2: 1-0-1-0 / 5-4-5-4 / / , D3: 1-0-1-0 / 6-5-6-5 / / , and offset padding yarn code D4: 1-1-1-0 / 5-5-5-4 / / , which only forms loops on the back needle bed.

[0015] Optionally, the first, second, third, and fourth ground combs can each be threaded with one of the following yarns: polyester, nylon, spandex, acrylic DTY, FDY, and POY, with a denier of 50-900D.

[0016] Optionally, the first, second, third, and fourth ground combs can each be threaded with a composite yarn of two or three of the following yarns: polyester, nylon, spandex, acrylic DTY, FDY, and POY, with denier ranging from 50 to 900D. Acrylic DTY refers to acrylic elastic textured yarn, FDY refers to fully drawn yarn, and POY refers to partially oriented yarn.

[0017] Optionally, the first, second, third, and fourth ground combs can be designed with padding yarn according to design requirements, ultimately forming a planar structure or a mesh structure on the product surface. The mesh structure can be circular, elliptical, square, rectangular, triangular, rhomboid, hexagonal, or trapezoidal.

[0018] The present invention achieves the following technical effects compared to the prior art:

[0019] This invention employs two Jacquard combs that can thread the same or different types of yarn separately, eliminating the need for yarn arrangement during the weaving process. This simplifies the process, reduces production intensity and difficulty, and improves production efficiency. Each section can be arranged arbitrarily along the weaving direction and width, rather than simply as unidirectional stripes along the width or longitudinal direction. The size and shape of each area of ​​the fabric are unrestricted, and each area can be made into any shape as needed. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the elastic partitioned braided product structure of the present invention;

[0022] Figure 2 This is a schematic cross-sectional view of the elastic partitioned knitted product of the present invention;

[0023] In the diagram: 1-First elastic zone, 2-Second elastic zone, 3-Third elastic zone, 4-Fourth elastic zone, 5-Fifth elastic zone, 6-Sixth elastic zone, 7-Seventh elastic zone, 8-Suture zone. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] The purpose of this invention is to provide a method for producing elastic partitioned knitted products to solve the problems existing in the prior art. By utilizing different offset signals of Jacquard combs, partitioned products of arbitrary shapes along the horizontal or vertical direction can be made, thereby achieving shape innovation of partitioned products.

[0026] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0027] This invention provides a method for producing elastic partitioned knitted products, such as... Figure 1 and Figure 2 As shown, this elastic zone woven product includes elastic zones 1, 2, 3, 4, 5, 6, and 7. Of course, an unlimited number of elastic zones can be set according to actual usage requirements. The elastic zones can be arbitrarily arranged along the weaving direction (longitudinal) or width direction (transverse) according to different shapes, sizes, and elastic sequences as required by the design. Furthermore, the compressive elasticity of each zone can be the same or different. This can be achieved through the following steps:

[0028] Step 1: According to the design requirements, thread the yarn of the required specifications and type onto the guide bar of the Jacquard knitting machine;

[0029] Step 2: Design the Jacquard pattern according to the flexible zoning requirements, and input the program into the control system of the Jacquard warp knitting machine;

[0030] Step 3: The first and second ground combs GB1 and GB2 are knitted on the front needle bed to form the upper surface, and the third and fourth ground combs GB5 and GB6 are knitted on the back needle bed to form the lower surface; the first Jacquard comb JB3 is inserted into the monofilament X, and the basic Jacquard padding number of the first Jacquard comb JB3 is A. Different Jacquard offset signals are set in different elastic partition areas, ultimately forming different offset padding numbers A1, A2, A3, and A4; the second Jacquard comb JB4 is inserted into the monofilament Y, and the basic Jacquard padding number of the second Jacquard comb JB4 is A. The basic Jacquard padding number is D. The same or different Jacquard offset signals are set in different elastic partition areas, and finally the offset padding numbers D1, D2, D3 and D4 are formed in each partition area. The first Jacquard comb JB3 and the second Jacquard comb JB4 are combined with the yarn type, the basic Jacquard padding number, the Jacquard offset signal and the synchronization degree of Jacquard comb weaving to form different compressive elastic areas whose shape, size and elasticity can be arbitrarily designed along the weaving direction (length direction) and the width direction (transverse direction) of the fabric.

[0031] The padding yarn numbers A and D of the first Jacquard comb JB3 and the second Jacquard comb JB4, the Jacquard offset signal, and the offset padding yarn numbers A1, A2, A3, A4, D1, D2, D3, D4 can also be other padding yarn numbers and Jacquard offset signals that can form different compressive elasticity regions after any combination.

[0032] This invention uses Jacquard combs for full warp threading. The offset of the Jacquard eliminates the need for different threading configurations, making the design convenient and easy for workers to operate. In some areas, the first and second Jacquard combs (JB3 and JB4) form loops on both the front and back needle beds, creating the first elastic zone 1, second elastic zone 2, and third elastic zone 3, which have high compressive elasticity. In other areas, one of the first and second Jacquard combs (JB3 and JB4) alternates between forming loops on the front and back needle beds, while the other combs loops individually on either the front or back needle bed, forming loops separately. Combined with monofilaments and padding yarns of varying bending stiffness, this creates the fourth elastic zone 4, fifth elastic zone 5, sixth elastic zone 6, and seventh elastic zone 7, which have lower compressive elasticity. In some areas, both the first and second Jacquard combs (JB3 and JB4) form loops individually on the front and back needle beds, respectively, creating a mattress sewing area without supporting spacers, facilitating mattress stitching. This invention utilizes different offset signals of Jacquard combs to create partitioned products with arbitrary shapes along the horizontal or vertical direction, breaking the barrier that the original partitioned products could only be arranged in a regular stripe pattern, and realizing the technological innovation that partitioned products can be made into arbitrary shapes.

[0033] Example 1

[0034] A compression-resistant elastic zoned knitting product of this embodiment can be produced on a Jacquard warp knitting machine of model RDJ6 / 2, equipped with four ground combs and two Jacquard combs, with a needle gauge of E22, and a draft density set to 18. cpc The opening width is set to 6.5-8.5mm. The yarn padding codes, Jacquard offset signals, yarn threading methods, and raw material types for the first Jacquard guide bar (JB3) and the second Jacquard guide bar (JB4) are shown in Table 1 and Table 2, respectively. The yarn padding codes and yarn threading methods for the first ground guide bar (GB1), the second ground guide bar (GB2), the third ground guide bar (GB5), and the fourth ground guide bar (GB6) are as follows:

[0035] GB1: 2-2-2-2 / 0-0-0-0 / 0-0-0-0 / 2-2-2-2 / 2-2-2-2 / 1-1-1-1 / 1-1-1-1 / 3-3-3-3 / 3-3-3-3 / 1-1-1-1 / 1-1-1-1 / 2-2-2-2 / / 150D Polyester DTY One Wear One Empty

[0036] GB2: 0-1-1-1 / 1-0-0-0 / / 150D polyester DTY full wear

[0037] GB5: 0-0-0-1 / 1-1-1-0 / / 150D polyester DTY full wear

[0038] GB6: 2-2-2-2 / 0-0-0-0 / 0-0-0-0 / 2-2-2-2 / 2-2-2-2 / 1-1-1-1 / 1-1-1-1 / 3-3-3-3 / 3-3-3-3 / 1-1-1-1 / 1-1-1-1 / 2-2-2-2 / / 150D polyester DTY, one wear, one empty.

[0039] Table 1. Yarn types and threading methods for the first Jacquard comb (JB3) and the second Jacquard comb (JB4).

[0040]

[0041] Table 2. Yarn padding numbers, Jacquard offset signals, and functions of the first Jacquard comb (JB3) and the second Jacquard comb (JB4) on the needle bed.

[0042]

[0043]

[0044]

[0045] like Figure 1 and Figure 2 As shown, the elastic zone knitted product in this embodiment includes a first elastic zone 1, a second elastic zone 2, a third elastic zone 3, a fourth elastic zone 4, a fifth elastic zone 5, a sixth elastic zone 6, a seventh elastic zone 7, and a seam zone 8. These eight zones are categorized by their firmness into hard, medium-soft, and soft zones, with the firmness decreasing sequentially. The first elastic zone 1, second elastic zone 2, and third elastic zone 3 are hard zones, but the third elastic zone 3 has the highest firmness, the first elastic zone 1 has a medium firmness, and the second elastic zone 2 has the lowest firmness. The fourth elastic zone 4 is a soft zone, and the fifth elastic zone 5 to the seventh elastic zone 7 are medium-soft zones, with the firmness also gradually decreasing from the fifth elastic zone 5 to the seventh elastic zone 7. Based on this combination, the firmness and width of each zone can be freely adjusted by changing the padding yarn number, padding yarn angle, and monofilament type.

[0046] The product in this embodiment is designed for use as a mattress. Therefore, the widths of the first elastic zone 1 to the seventh elastic zone 7 are 22cm, 42cm, 22cm, 44cm, 22cm, 42cm, and 22cm, respectively. The firmness of each zone is as follows: the fourth elastic zone 4 is the softest, providing excellent support for the buttocks and relieving pressure. The first elastic zones 1 to the third elastic zone 3 need to support the relatively heavy weight of the upper body, so they are set as firm zones. The first elastic zone 1 corresponds to the head, and its firmness can be adjusted using Jacquard signal offsets to achieve a medium firmness. The second elastic zone 2 corresponds to the shoulder, chest, and back areas, requiring appropriate support for the shoulder area. For the hard zone, the softest padding yarn numbers after Jacquard signal offset are selected: JB3 as 0-1-0-1 / 5-6-5-6 / / and JB4 as 1-0-1-0 / 6-5-6-5 / / . The third elastic zone 3 corresponds to the human waist, which requires strong support. Therefore, the hardest padding yarn numbers after Jacquard signal offset are selected: JB3 as 1-2-1-2 / 4-5-4-5 / / and JB4 as 2-1-2-1 / 5-4-5-4 / / to achieve additional hardness. The fifth elastic zone (5) to the seventh elastic zone (7) only need to support the relatively light weight of the lower body, so they are set as medium-soft zones. The fifth elastic zone (5) corresponds to the thigh, which is the heaviest area of ​​the lower limbs, so its firmness is achieved by using the Jacquard signal offset to adjust the padding yarn's digital values: JB3 is 1-2-1-2 / 4-5-4-5 / / and JB4 is 1-1-1-0 / 5-5-5-4, making it the firmest part of the medium-soft zone. The sixth elastic zone (6) corresponds to the lower leg and knee, where the body weight is moderate, so its firmness... The medium-soft zone is achieved by using the Jacquard signal offset to set the padding yarn digital values ​​JB3 as 0-1-0-1 / 4-5-4-5 / / and JB4 as 1-1-1-0 / 5-5-5-4. The seventh elastic zone, corresponding to the human ankle, is the lightest part, but the bone protrudes, requiring a strong sense of containment. Therefore, the softness of the padding yarn is achieved by using the Jacquard signal offset to set the padding yarn digital values ​​JB3 as 0-1-0-1 / 5-6-5-6 / / and JB4 as 1-1-1-0 / 5-5-5-4. In the sewing area 8, the first Jacquard guide bar JB3 is woven into a loop only on the front needle bed along with the first ground guide bar GB1 and the second ground guide bar GB2. The second Jacquard guide bar JB4 is woven into a loop only on the rear needle bed along with the third ground guide bar GB5 and the fourth ground guide bar GB6. This creates a structure with only upper and lower surfaces and no interlayer yarns, facilitating sewing, hemming, and cutting. In this embodiment, two Jacquard guide bars can be threaded with the same or different types of yarn respectively, eliminating the need for yarn arrangement during the weaving process. This simplifies the process, reduces production intensity and difficulty, and improves production efficiency.Each section can be arranged arbitrarily along the weaving direction and width direction, rather than just unidirectional stripes along the width or longitudinal direction. The size and shape design of each area of ​​the fabric are unrestricted, and each area can be made into any shape as needed.

[0047] The above are merely specific embodiments of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention using this concept shall be considered as infringing upon the protection scope of the present invention.

[0048] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method for producing an elastically partitioned woven product, characterized in that, Includes the following steps: Step 1: According to the design requirements, thread the yarn of the required specifications and type onto the guide bar of the Jacquard knitting machine; Step 2: Design the Jacquard pattern according to the flexible zoning requirements, and input the Jacquard pattern program into the control system of the Jacquard warp knitting machine; Step 3: The first and second ground combs are knitted on the front needle bed to form the upper surface, and the third and fourth ground combs are knitted on the back needle bed to form the lower surface; the first Jacquard comb is inserted into monofilament X, and the basic Jacquard padding code of the first Jacquard comb is A. Different Jacquard offset signals are set in different elastic partition areas, ultimately forming different offset padding codes A1, A2, A3, and A4; the second Jacquard comb is inserted into monofilament Y, and the basic Jacquard padding code of the second Jacquard comb is D. The same or different Jacquard offset signals are set in different elastic partition areas. The final offset padding numbers D1, D2, D3, and D4 are formed in each zone. The first and second Jacquard combs, through the interaction of yarn type, basic Jacquard padding numbers, Jacquard offset signals, and the synchronization of Jacquard comb weaving, form compression-resistant elastic zones with different shapes, sizes, and elasticities along the fabric weaving direction and fabric width direction. The basic Jacquard padding number A of the first Jacquard comb is selected as 0-1-0-1 / 4-5-4-5 / / , and different Jacquard offset signals are set at different zone positions as follows: TTTT HHHH, HHHH HHHH, HHHH TTTT, HHTH HHTH, ultimately forming different offset backfill yarn numbers for each elastic zone, which alternately loop on the front and back needle beds: A1: 1-2-1-2 / 4-5-4-5 / / , A2: 0-1-0-1 / 4-5-4-5 / / , A3: 0-1-0-1 / 5-6-5-6 / / , and an offset backfill yarn number A4: 0-1-1-1 / 4-5-5-5 / / , which only loops on the front needle bed; the Jacquard basic backfill yarn number D of the second Jacquard guide bar is selected as 1-0-1-0 / 5-4-5-4 / / , and different Jacquard offset signals are set at different elastic zone positions: TTTT HHHH, HHHH HHHH, HHHH TTTT, HTHH HTHH ultimately results in different offset back pad yarn numbers for each elastic zone, which alternately form loops on the front and back needle beds: D1: 2-1-2-1 / 5-4-5-4 / / , D2: 1-0-1-0 / 5-4-5-4 / / , D3: 1-0-1-0 / 6-5-6-5 / / , and offset back pad yarn number D4: 1-1-1-0 / 5-5-5-4 / / , which only forms loops on the back needle bed.

2. The method for producing the elastic partitioned knitted product according to claim 1, characterized in that, The monofilaments X and Y are monofilaments with different diameters, both between 0.05 and 0.5 mm.

3. The method for producing the elastic partitioned knitted product according to claim 1, characterized in that, The monofilaments X and Y are monofilaments with different bending stiffnesses. Both monofilaments X and Y are one of polyester monofilament, nylon monofilament, polypropylene monofilament, or modified polyester filament, or they are composite monofilaments with a core-sheath structure composed of two of the following: polyester monofilament, nylon monofilament, polypropylene monofilament, or modified polyester filament.

4. The method for producing an elastic partitioned knitted product according to claim 1, characterized in that, The first, second, third, and fourth ground combs can respectively insert one of the following yarns: polyester, nylon, spandex, acrylic DTY, FDY, and POY.

5. The method for producing an elastic partitioned knitted product according to claim 1, characterized in that, The first, second, third, and fourth ground combs can respectively thread in composite yarns of two or three of the following: polyester, nylon, spandex, acrylic DTY, FDY, and POY.

6. The method for producing an elastic partitioned knitted product according to claim 1, characterized in that, The first, second, third, and fourth ground combs can be designed with padding yarn according to design requirements, ultimately forming a planar structure or a mesh structure on the product surface. The mesh structure can be circular, elliptical, square, rectangular, triangular, rhomboid, hexagonal, or trapezoidal.

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