A local single-layer warp-knitted convex-concave fabric and a production method thereof

Abstract

The application relates to a partial single-layer warp-knitted concave-convex fabric and a production method thereof, and belongs to the technical field of textiles. The partial single-layer warp-knitted concave-convex fabric comprises concave structure units and convex structure units. The concave structure units comprise single-layer fabric parts, and the convex structure units comprise multi-layer interval fabric parts. The multi-layer interval fabric parts comprise first surface layers, interval layers and second surface layers. The interval layers are located between the first surface layers and the second surface layers, and connect the first surface layers and the second surface layers. At least part of the concave structure units and the convex structure units are connected. The application can form the warp-knitted concave-convex fabric with the single-layer fabric parts and the multi-layer fabric parts at the same time, improves the safety and practicability of the warp-knitted concave-convex fabric, and meets market demand and market prospects.

Description

Technical Field

[0001] This invention belongs to the field of weaving technology, specifically relating to a partially single-layer warp-knitted textured fabric and its production method. Background Technology

[0002] Warp-knitted fabrics typically include single-layer, single-sided fabrics and multi-layer spacer fabrics. With the improvement of people's living standards, there are higher requirements for the comfort, functionality (breathability, cushioning, etc.), and aesthetics of warp-knitted fabrics. For example, in shoe uppers, wearers want the multi-layer spacer fabric areas to have a certain thickness to protect the feet during walking and running, while also wanting the single-layer fabric areas to provide breathability during walking. Similarly, in the fabric coverings of electronic products such as mobile phones, wearers want the multi-layer spacer fabric areas to provide cushioning and elasticity to protect the product from drops, while also wanting the single-layer fabric areas to better dissipate heat. Therefore, warp-knitted fabrics that combine single-layer and multi-layer spacer fabrics not only enrich the variety of warp-knitted fabrics but also have broad market application prospects.

[0003] Warp-knitted fabrics exhibit a textured effect, which can enhance their decorative appeal, improve their feel, breathability, and cushioning. The textured effect in warp-knitted fabrics typically occurs in two ways: First, the warp-knitted fabric uses elastic materials. The shrinkage of the elastic material causes the fabric to arch, creating a textured effect across the entire piece. Alternatively, the shrinkage of the elastic material can create a quilted effect on a fabric of a certain thickness, resulting in a visually varying thickness. Second, the guide bars are open-weave, resulting in sections that are single-layered fabric and sections that are multi-layered spacer fabric along the width. A high-contrast textured effect can be created by increasing the thickness of the spacer layers. However, this textured effect is only in the width direction, and the width of each section is the same in the weave direction. It is impossible to achieve the textured effect created by combining single-layered and multi-layered spacer fabrics along the entire weave direction. Summary of the Invention

[0004] This invention application proposes a partially single-layer warp-knitted textured fabric and its production method, aiming to partially or completely solve the technical problem that existing double-needle bed grooved needle warp knitting machines without Jacquard cannot achieve a high-contrast textured effect by combining single-layer and multi-layer spaced fabrics in the weaving direction of the fabric. The technical solution of this invention application is as follows:

[0005] In a first aspect, a partially single-layer warp-knitted textured fabric includes: concave structural units and convex structural units; the concave structural unit includes a single-layer fabric portion, and the convex structural unit includes multiple layers of spaced fabric portions, the multiple layers of spaced fabric portions including a first surface layer, a spacer layer, and a second surface layer, the spacer layer being located between the first surface layer and the second surface layer, and the spacer layer connecting the first surface layer and the second surface layer; at least a portion of the concave structural units and the convex structural units are connected.

[0006] Optionally, along the thickness direction of the fabric, the thickness of the spacer layer ranges from 1.2mm to 800mm, and the spacer layer includes spacer yarns made of 20D-400D yarns; the raw material of the first outer layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn, and the raw material of the second outer layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn.

[0007] Optionally, multiple concave structural units and multiple convex structural units are provided. Along the thickness direction of the fabric, the thicknesses of the multiple concave structural units are not exactly the same, and the thicknesses of the multiple convex structural units are not exactly the same.

[0008] Secondly, a method for producing a partially single-layer warp-knitted textured fabric, comprising:

[0009] Step S100: Based on the pattern of the warp-knitted embossed fabric, calculate the number of warp heads per guide bar and the number of head patterns per guide bar on a double needle bed warp knitting machine without jacquard, and then warp the fabric on the warping machine.

[0010] Step S200: Weaving on a double-needle bed grooved warp knitting machine without jacquard, multiple concave structural units and multiple convex structural units are formed along the weaving direction of the fabric. At least some of the concave structural units and convex structural units are connected. The convex structural units include multiple layers of spaced fabric sections, and the concave structural units include a single layer of fabric section, thereby obtaining a warp-knitted concave-convex fabric greige.

[0011] Step S300: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric.

[0012] Optionally, step SF is included before step S100: selecting a double-needle bed warp knitting machine without jacquards, which includes at least the first guide bar, the second guide bar, and the third guide bar, based on the width, number of widths, horizontal density, and pattern of the finished warp-knitted textured fabric, and selecting at least the machine width, machine number, and number of guide bars of the double-needle bed warp knitting machine without jacquards.

[0013] Optionally, in step S200, the multi-layer spacer fabric section includes a first outer layer, a spacer layer, and a second outer layer. The spacer layer is located between the first and second outer layers and connects the first and second outer layers. Each guide bar of the double-needle bed grooved needle warp knitting machine without jacquards threads yarn according to the warp threading rule. All guide bars form a single-layer fabric section by padding yarn on one side of the needle bed. For the multi-layer spacer fabric section, at least one first guide bar knits the first outer layer only on the front needle bed, at least one second guide bar knits the second outer layer only on the rear needle bed, and at least one third guide bar knits the spacer layer by padding yarn on both the front and rear needle beds to connect the first and second outer layers.

[0014] Optionally, in step S200, along the fabric width direction, the width of the concave structural unit and the width of the convex structural unit are determined at least by the number of comb passes, the number of transverse needles, the machine number, and the fabric shrinkage rate of the double needle bed groove needle warp knitting machine without Jacquard.

[0015] Optionally, in step S200, along the weaving direction of the fabric, the length of the concave structural unit is determined by the number of rows in which all guide bars form loops on a single needle bed, the weaving density, and the longitudinal shrinkage of the fabric; the length of the convex structural unit is at least determined by the number of rows in which the corresponding guide bars form loops with padding yarn on both the front and back needle beds, the weaving density, and the longitudinal shrinkage of the fabric.

[0016] Compared with the prior art, the beneficial effects achieved by this invention application are as follows:

[0017] (1) In this invention application, the warp-knitted embossed fabric includes concave structural units and convex structural units. The convex structural units include multiple layers of spaced fabric portions, and the concave structural units include a single layer of fabric portion. At least some of the concave structural units and convex structural units are connected. In this way, by connecting at least some of the concave structural units and convex structural units, a warp-knitted embossed fabric that simultaneously possesses a single layer of fabric portion and multiple layers of fabric portion can be integrally formed, making the warp-knitted embossed fabric more durable and less prone to loosening, improving the safety and practicality of the warp-knitted embossed fabric, and meeting market demand and market prospects.

[0018] (2) In this invention application, the production method of partially single-layer warp-knitted textured fabric can form a single-layer fabric part and a multi-layer spaced fabric part to meet different functional needs in daily life. For example, the single-layer fabric part can provide the function of being lightweight and close-fitting, while the multi-layer spaced fabric part can provide functions such as cushioning and support. Each guide bar is threaded with yarn according to the warp threading rule and knitted on a double-needle bed grooved needle warp knitting machine without jacquard, which can directly knit the fabric without sewing, reduce production errors, improve production efficiency, and ensure the stability of product quality. The knitting method of the guide bar can also be flexibly adjusted to create a variety of warp-knitted textured fabrics with different appearances and properties, which can meet the diverse requirements of fashion and functional design.

[0019] (3) In this invention application, the spacer layer is located between the first surface layer and the second surface layer. The spacer layer connects the first surface layer and the second surface layer, and also forms a warp-knitted textured fabric with a local multi-layered fabric part and a large contrast textured effect, which enhances the three-dimensionality and hand feel of the warp-knitted textured fabric, so that the warp-knitted textured fabric has one or more functions such as pressure resistance, breathability, and cushioning, and can also form a solid color or multi-color three-dimensional pattern effect to meet the market's demand for fashion and beauty of fabrics. Attached Figure Description

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

[0021] Figure 1 This is a schematic diagram of a partially single-layer warp-knitted textured fabric A structure according to the present invention.

[0022] Figure 2 This is a schematic diagram of a partially single-layer warp-knitted textured fabric B structure according to the present invention.

[0023] Figure 3 This is a schematic diagram of a partially single-layer warp-knitted textured fabric C structure according to the present invention.

[0024] Figure 4 This is a flowchart illustrating a method for producing a partially single-layer warp-knitted textured fabric according to this application.

[0025] Figure 5 This is a schematic diagram illustrating the movement of the comb and pad yarns of a partially single-layer warp-knitted textured fabric A according to this invention application.

[0026] Figure 6 This is a schematic diagram illustrating the movement of the comb and pad yarns of a partially single-layer warp-knitted textured fabric B according to this invention.

[0027] Figure 7 This is a schematic diagram illustrating the movement of the comb and pad yarns in a partially single-layer warp-knitted textured fabric C, as described in this invention application.

[0028] The accompanying drawings are provided to further understand the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation thereof. Detailed Implementation

[0029] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0030] In the description of this invention application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means one, two, or more than two, unless otherwise explicitly specified.

[0032] In this invention application, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, an integral molding, or an integrated unit; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0033] To make the objectives, technical solutions, and advantages of this invention application clearer, the embodiments of this invention application will be described in further detail below with reference to the accompanying drawings.

[0034] Exemplary description of a partially single-layer warp-knitted textured fabric

[0035] like Figures 1 to 3As shown, in a first aspect, a partially single-layer warp-knitted textured fabric includes: a concave structural unit 100 and a convex structural unit 200; the concave structural unit 100 includes a single-layer fabric portion; the convex structural unit 200 includes multiple layers of spacer fabric portions, each layer including a first surface layer, a spacer layer, and a second surface layer, the spacer layer being located between the first surface layer and the second surface layer, and the spacer layer connecting the first surface layer and the second surface layer; at least a portion of the concave structural unit 100 and the convex structural unit 200 are connected.

[0036] In a partially single-layer warp-knitted textured fabric of this invention, the warp-knitted textured fabric first includes concave structural units 100 and convex structural units 200. The concave structural unit 100 includes a single-layer fabric portion, and the convex structural unit 200 includes multiple layers of spaced fabric portions. The connection of at least some of the concave structural units 100 and convex structural units 200 can mean that: at least some of the concave structural units 100 and convex structural units 200 are connected along the weaving direction of the fabric (e.g., the X direction); and / or, at least some of the concave structural units 100 and convex structural units 200 are connected along the width direction of the fabric (e.g., the Y direction). In this way, by connecting at least some concave and convex structural units, a warp-knitted textured fabric with both single-layer and multi-layer fabric sections can be integrally formed. This makes the warp-knitted textured fabric more durable and less prone to loosening, improving its safety and practicality, and meeting market demands and prospects. In addition, the spacer layer is located between the first and second surface layers, connecting them to form a warp-knitted textured fabric with locally multi-layer fabric sections and a high-contrast textured effect. This enhances the three-dimensionality and feel of the warp-knitted textured fabric, giving it one or more functions such as pressure resistance, breathability, and cushioning. It can also create solid-color or multi-color three-dimensional floral patterns, meeting the market's demand for fashionable and aesthetically pleasing fabrics.

[0037] Optionally, along the thickness direction of the fabric, the thickness of the spacer layer ranges from 1.2mm to 800mm, and the spacer layer includes spacer yarns made of 20D-400D yarns; the raw material of the first outer layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn, and the raw material of the second outer layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn.

[0038] In this invention application, the thickness of the interlayer in the fabric's thickness direction (e.g., the Z direction) ranges from 1.2mm to 800mm, providing a wide range of applications for warp-knitted textured fabrics, satisfying needs from thin to heavy. Using 20D-400D yarn as interlayer yarn ensures the stability and strength of the interlayer, making it suitable for various pressures and operating environments. Both the first and second outer layers can be made of one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn. These materials possess excellent abrasion resistance, elasticity, and chemical stability, making the fabric suitable for various environments and applications. The fabric's good abrasion resistance, tear resistance, and resilience make it more durable and suitable for manufacturing various fabric products.

[0039] Optionally, multiple concave structural units 100 and multiple convex structural units 200 are provided. Along the thickness direction of the fabric, the thicknesses of the multiple concave structural units 100 and the multiple convex structural units 200 are not exactly the same.

[0040] In this invention application, at least some concave structural units 100 and convex structural units 200 can be adjacent and connected, or at least some concave structural units 100 and convex structural units 200 can be alternately arranged and connected; along the thickness direction of the fabric (e.g., the Z direction), the thicknesses of the concave structural units 100 and convex structural units 200 are different, forming a distinct concave-convex effect on the fabric surface, which can achieve a high-contrast concave-convex effect, increasing the visual three-dimensionality and aesthetics; units of different thicknesses can be adjusted according to design requirements, so that the fabric can adapt to different application scenarios; concave structural units can increase air circulation between the fabric and the skin, improving the comfort of wearing or using; multiple concave structural units 100 and convex structural units 200 with different thicknesses may help improve the mechanical properties of the fabric, such as tensile and compressive strength.

[0041] In some embodiments, along the width direction of the fabric (e.g., the Y direction), the widths of the plurality of concave structural units 100 are exactly the same or not exactly the same, the widths of the plurality of convex structural units 200 are exactly the same or not exactly the same, and along the weaving direction of the fabric (e.g., the X direction), the lengths of the plurality of concave structural units 100 are exactly the same or not exactly the same, and the lengths of the plurality of concave structural units 200 are exactly the same or not exactly the same.

[0042] In some embodiments, the X, Y, and Z directions intersect each other. Preferably, the X, Y, and Z directions are perpendicular to each other, forming a 90-degree angle. The X direction may represent the weaving direction of the fabric, the Y direction may represent the width direction of the fabric, and the Z direction may represent the thickness direction of the fabric.

[0043] Exemplary description of a method for producing partially single-layer warp-knitted textured fabric

[0044] like Figure 4 As shown, in a second aspect, a method for producing a partially single-layer warp-knitted textured fabric, comprising the following steps:

[0045] Step S100: Based on the pattern of the finished warp-knitted embossed fabric, calculate the number of warp heads per guide bar and the number of head patterns per guide bar on a double needle bed warp knitting machine without jacquard, and then warp the fabric on the warping machine.

[0046] Step S200: A double-needle bed warp knitting machine without jacquard knitting is used to knit multiple concave structural units 100 and multiple convex structural units 200 along the knitting direction of the fabric; at least some of the concave structural units 100 and convex structural units 200 are connected, the convex structural unit 200 includes multiple layers of spaced fabric, and the concave structural unit 100 includes a single layer of fabric, thereby obtaining a warp-knitted concave-convex fabric greige.

[0047] Step S300: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric.

[0048] In a method for producing a partially single-layer warp-knitted textured fabric according to this invention, firstly, the production process of the partially single-layer warp-knitted textured fabric allows for independent adjustment and control of the warping steps of the warping machine, the weaving steps of the double-needle bed warp knitting machine without jacquard, and the finishing and dyeing steps (e.g., production process parameters). For example, in the warping step of the warping machine, the number of warping heads and the number of warp threads per guide bar can be calculated to ensure precise warping on the warping machine, thus ensuring the consistency and quality of the finished product. Furthermore, the overall production method can reduce errors and waste during the production process. Moreover, through pre-setting, dyeing, and post-setting steps, the fabric's hand feel, color uniformity, and dimensional stability can be improved, enhancing the appearance quality and performance of the finished product, and increasing production efficiency. The yield rate of the fabric; in addition, the warp-knitted textured fabric includes concave structural units 100 and convex structural units 200. The convex structural unit 200 includes multiple layers of spaced fabric portions, and the concave structural unit 100 includes a single layer of fabric portion. Along the weaving direction of the fabric can also mean: at least along the weaving direction of the fabric, which may also include along the weaving direction of the fabric and along the width direction of the fabric. At the same time, the connection of at least some of the concave structural units 100 and convex structural units 200 can also mean: along the weaving direction of the fabric (e.g., the X direction), at least some of the concave structural units 100 and convex structural units 200 are connected; and / or, along the width direction of the fabric (e.g., the Y direction), at least some of the concave structural units 100 and convex structural units 200 are connected. In this way, by connecting at least some concave structural units 100 and convex structural units 200, a warp-knitted embossed fabric with both single-layer and multi-layer fabric parts can be formed in one piece, which enhances the three-dimensionality and visual effect of the fabric, makes the warp-knitted embossed fabric more durable and less prone to loosening, improves the safety and practicality of the warp-knitted embossed fabric, and meets market demand and market prospects.

[0049] Optionally, step SF is included before step S100: selecting a double-needle bed warp knitting machine without jacquards, which includes at least the first guide bar, the second guide bar, and the third guide bar, based on the width, number of widths, horizontal density, and pattern of the finished warp-knitted textured fabric, and selecting at least the machine width, machine number, and number of guide bars of the double-needle bed warp knitting machine without jacquards.

[0050] In this invention application, selecting a double-needle bed warp knitting machine and its parameters without jacquard based on the width, number of widths, warp density, and pattern of the finished fabric ensures a high degree of compatibility between the machine and product requirements, thereby improving production efficiency and product quality. A reasonable machine configuration helps simplify the production process, reduce unnecessary adjustments and downtime, improve production continuity and stability, and make subsequent weaving processes smoother. Different machine sizes and guide bar numbers can adapt to different pattern designs, creating complex patterns and structures in warp-knitted textured fabrics, making products more diversified, increasing market competitiveness, and meeting market demand for personalized products.

[0051] Optionally, in step S200, the multi-layer spacer fabric section includes a first outer layer, a spacer layer, and a second outer layer. The spacer layer is located between the first and second outer layers and connects the first and second outer layers. Each guide bar of the double-needle bed grooved needle warp knitting machine without jacquards threads yarn according to the warp threading rule. All guide bars form a single-layer fabric section by padding yarn on one side of the needle bed. For the multi-layer spacer fabric section, at least one first guide bar knits the first outer layer only on the front needle bed, at least one second guide bar knits the second outer layer only on the rear needle bed, and at least one third guide bar knits the spacer layer by padding yarn on both the front and rear needle beds to connect the first and second outer layers.

[0052] In this invention application, firstly, the warp-knitted textured fabric is formed with a single-layer fabric section and multiple-layer spacer fabric sections to meet different functional requirements. For example, the single-layer fabric section can provide a lightweight and close-fitting function, while the multiple-layer spacer fabric sections can provide cushioning and support functions. Each guide bar is threaded with yarn according to the warp threading pattern and knitted on a double-needle bed grooved needle warp knitting machine without jacquards, which can directly knit the fabric without sewing, reducing production errors, improving production efficiency, and ensuring the stability of product quality. It can also flexibly adjust the knitting method of the guide bar to create a variety of warp-knitted textured fabrics with different appearances and properties to meet the diverse requirements of fashion and functional designs. In addition, the spacer layer is knitted with padding yarn on both the front and back needle beds. This flexible and diverse knitting method makes the production process more flexible and can be adjusted according to different design requirements and production conditions. At the same time, different knitting positions can adjust the spacer yarn density and fabric thickness, thereby optimizing the connection strength and stability between the spacer layer and the surface layer and improving the cushioning performance of the multi-layer spacer fabric.

[0053] Optionally, in step S200, along the width direction of the fabric, the width of the concave structural unit 100 and the width of the convex structural unit 200 are determined at least by the number of comb passes, the number of transverse needles, the machine number, and the fabric shrinkage rate of the double needle bed groove needle warp knitting machine without Jacquard.

[0054] In this invention application, in step S200, the width of the concave structural unit 100 and the convex structural unit 200 are determined based on the number of guide bar stitches, the number of transverse stitches, the machine number, and the fabric shrinkage of the double needle bed warp knitting machine without Jacquard. This enables control over the width dimensions, ensuring that the concave and convex structural dimensions of the fabric in the width direction meet the design expectations. Moreover, the production process is more standardized and repeatable, reducing errors caused by human factors or other uncertainties, and ensuring the stability of product quality. At the same time, by adjusting and optimizing these parameters, concave and convex structures of different widths can be created to obtain concave and convex effects with different contrasts, providing rich variations for fabric design and meeting specific or diversified market demands.

[0055] Optionally, in step S200, along the weaving direction of the fabric, the length of the concave structural unit is determined by the number of rows in which all guide bars form loops on a single needle bed, the weaving density, and the longitudinal shrinkage of the fabric; the length of the convex structural unit is at least determined by the number of rows in which the corresponding guide bars form loops with padding yarn on both the front and back needle beds, the weaving density, and the longitudinal shrinkage of the fabric.

[0056] In this invention application, in step S200, by adjusting the number of loops of the padding yarn on the front and rear needle beds, the weaving density and the longitudinal shrinkage rate of the fabric, the length of the concave structural unit 100 and the convex structural unit 200 can be precisely controlled to achieve the three-dimensional effect required by the design. Precise design and control can reduce errors and waste in production, and improve production efficiency and fabric yield.

[0057] Partially single-layer warp-knitted textured fabric A, partially single-layer warp-knitted textured fabric B, and partially single-layer warp-knitted textured surface Example description of the production method of material C

[0058] The following section uses three types of partially single-layer warp-knitted textured fabrics as examples, referred to as partially single-layer warp-knitted textured fabric A, partially single-layer warp-knitted textured fabric B, and partially single-layer warp-knitted textured fabric C, to introduce the production methods of each type.

[0059] (1) Production method of warp-knitted textured fabric with partial single layer A

[0060] like Figure 1 , Figure 5 As shown, the partial single-layer warp-knitted textured fabric A includes: a finished width of 142cm, woven into 2 widths, a horizontal density of 11wpc, a pattern including raised horizontal stripes, and a single-layer fabric section including a thick plain fabric.

[0061] Step SFA: Based on the width, number of widths, horizontal density and pattern of the finished warp-knitted textured fabric A, select a double-needle bed warp knitting machine RD7 without jacquard, machine number E24, 140 inches, 7 guide bars, actual use of 3 guide bars, and a loop release plate distance of 3.5mm.

[0062] Step S100A: Based on the pattern of the single-layer warp-knitted textured fabric A, and according to the warping process of each guide bar, GB1, GB2, GB6, and GB7 do not require warping. The warping parameters for GB3, GB4, and GB5 are as follows: GB3: 528*6A, GB4: 528*6B, GB5: 528*6C, A: 200D / 96F polyester DTY, B: 30D polyester monofilament, C: 150D / 48F polyester cationic.

[0063] Step S200A: Weaving on a double-needle bed warp knitting machine RD7 without jacquard, with a pattern height of 24 rows, a pattern width of 6 warp rows, and a machine density of 16 cpc. Guide bars GB1, GB2, GB6, and GB7 are woven loosely, while guide bars GB3, GB4, and GB5 are woven fully. In rows 1-6, guide bars GB3, GB4, and GB5 are all looped on the front needle bed yarn, and guide bars GB3 and GB5 are symmetrically padded in opposite directions, forming a concave structural unit 101A (100). In rows 7-12, GB3 is looped only on the front needle bed yarn, GB4 is looped on both the front and back needle beds, and GB5 is looped only on the back needle bed yarn, forming a convex structural unit 201A (200). In rows 13-18, guide bars GB3, GB4, and GB5 are all looped on the back needle bed yarn, forming a concave structural unit 102A. (100); In rows 19-24, GB3 forms loops only in the front needle bed yarn, GB4 forms loops in both the front and rear needle beds, and GB5 forms loops only in the back needle bed yarn, forming a convex structural unit 202A (200). The double-needle bed grooved warp knitting machine RD7 without jacquard continues to perform weaving operations according to the preset rules. Along the weaving direction of the fabric, multiple concave structural units 100 and multiple convex structural units 200 will be formed. Along the weaving direction of the fabric, at least some of the concave structural units 100 and convex structural units 200 are connected. The concave structural unit 100 includes a single-layer fabric section, and the convex structural unit 200 includes multiple layers of spaced fabric sections, thereby obtaining a warp-knitted concave-convex fabric greige. Among them, the weaving parameters (guide bar, padding yarn number, yarn threading parameters) of the double-needle bed grooved warp knitting machine RD7 without jacquard include at least:

[0064]

[0065] Step S300A: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric A.

[0066] (2) Production method of warp-knitted textured fabric with partial single layer B

[0067] like Figure 2 , Figure 6 As shown, the partially single-layer warp-knitted textured fabric B includes: a finished width of 142cm, woven into 2 widths, a warp density of 11wpc, a pattern including lines, a single-layer fabric section including a mesh structure, and convex structural units of different widths.

[0068] Step SFB: Based on the width, number of widths, horizontal density and pattern of the finished warp-knitted textured fabric B, select a double-needle bed warp knitting machine RD7 without jacquard, machine number E24, 140 inches, 7 guide bars, actual number of guide bars used is 6, and the distance between the loop release plates is 3mm.

[0069] Step S100B: Based on the pattern of the partial single-layer warp-knitted textured fabric B, and according to the warping process of each guide bar, GB1 does not require warping. The warping parameters of GB2, GB3, GB4, GB5, GB6, and GB7 are as follows: GB2: 110*6A, GB3: 110*6A, GB4: 110*6B, GB5: 110*6B, GB6: 396*6C, GB7: 396*6C, A: 150D / 48F polyester black yarn, B: 150D / 48F polyester cationic yarn, C: 30D polyester monofilament.

[0070] Step S200B: Knitted on a double-needle bed warp knitting machine RD7 without jacquard, with a pattern height of 30 rows and a pattern width of 24 columns, and a machine density of 15.4 cpc. Guide bars GB2 and GB3 are knitted only on the front needle bed according to a certain yarn threading pattern. Guide bars GB4 and GB5 are knitted alternately on the front and rear needle beds according to a certain pattern to form loops. Guide bars GB6 and GB7 are knitted three times and one time, forming a mesh structure only on the back needle bed. The convex structure unit 201B (200) is knitted by GB2, GB3, GB4, GB5, GB6, and GB7. The concave structure unit 101B (100) is knitted by guide bars. The GB6 and GB7 combs are woven in loops on the back needle bed yarn. The RD7 double-needle bed warp knitting machine without jacquard continues the weaving operation according to a preset pattern. Along the weaving direction of the fabric, multiple concave structural units 100 and multiple convex structural units 200 are formed, with at least some of the concave structural units 100 and convex structural units 200 connected. Each concave structural unit 100 includes a single-layer fabric section, and each convex structural unit 200 includes multiple layers of spaced fabric sections, thus obtaining a warp-knitted concave-convex fabric greige. The weaving parameters (comb, pad yarn numbers, and yarn threading parameters) of the RD7 double-needle bed warp knitting machine without jacquard include at least:

[0071]

[0072]

[0073] Step S300B: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric B.

[0074] (3) Production method of warp-knitted textured fabric with partial single layer

[0075] like Figure 3 , Figure 7 As shown, the partially single-layer warp-knitted textured fabric C includes: a finished width of 142cm, woven into 2 widths, a warp density of 11wpc, a pattern including a square pattern, a single-layer fabric section including a plain weave, and convex structural units of different widths.

[0076] Step SFC: Based on the width, number of widths, horizontal density and pattern of the finished warp-knitted textured fabric C, select a double-needle bed warp knitting machine RD7 without jacquard, machine number E24, 140 inches, 7 guide bars, actual number of guide bars used is 7, and the distance between the loop release plates is 3.5mm.

[0077] Step S100C: Based on the pattern of the single-layer warp-knitted textured fabric C, and according to the warping process of each guide bar, the warping parameters of guide bars GB1, GB2, GB3, GB4, GB5, GB6, and GB7 are as follows: GB1: 132*6A, GB2: 132*6A, GB3: 396*6B, GB4: 396*6B, GB5: 132*6C, GB6: 396*6C, GB7: 528*6D, A: 150D / 48F polyester, B: 150D / 48F polyester black yarn, C: 30D polyester monofilament, D: 100D / 36F polyester cationic yarn.

[0078] Step S200C: Weaving on a double-needle bed warp knitting machine RD7 without jacquard, with a pattern height of 24 rows and a pattern width of 16 warp rows, and a machine density of 15.4 cpc. Guide bars GB1 and GB2 only form loops on the front needle bed, creating a dense weave. Guide bar GB5 alternately forms loops on the front and rear needle beds. Guide bars GB1, GB2, GB5, and GB7 form convex structural units 2011C (200) according to a certain rule. Guide bars GB3 and GB4 form loops only on the front needle bed in convex structural unit 2012C (200) and only on the back needle bed in concave structural unit 101C (200). GB6 alternately forms loops on the front and rear needle beds in convex structural unit 2012C (200) and only on the back needle bed in concave structural unit 101C (100). The GB3, GB4, GB6, and GB7 combs, following a certain rule of yarn threading, form convex structural units 2012C (200) and concave structural units 101C (100). The GB7 comb only weaves the base fabric in loops on the back needle bed yarn. The RD7 double-needle bed warp knitting machine without jacquard continues to weave according to a preset pattern. Along the weaving direction of the fabric, multiple concave structural units 100 and multiple convex structural units 200 are formed, with at least some of the concave structural units 100 and convex structural units 200 connected. The concave structural unit 100 includes a single-layer fabric section, and the convex structural unit 200 includes multiple layers of spaced fabric sections, thereby obtaining a warp-knitted concave-convex fabric base. The weaving parameters (comb, yarn padding, and yarn threading parameters) of the RD7 double-needle bed warp knitting machine without jacquard include at least the following:

[0079] Comb Yarn Padding Digital Wearing gauze GB1 1-0-1-1 / 1-2-1-1 / / 4A,12* GB2 1-2-1-1 / 1-0-1-1 / / 4A,12* GB3 (1-0-1-1 / 1-2-1-1)*6 / (1-1-1-0 / 1-1-1-2)*6 / / 4*,12B GB4 (1-2-1-1 / 1-0-1-1)*6 / (1-1-1-2 / 1-1-1-0)*6 / / 4*,12B GB5 1-0-1-0 / 0-1-0-1 / / 4C,12* GB6 (1-0-1-0 / 0-1-0-1)*6 / (1-1-1-0 / 0-0-0-1)*6 / / 4*,12C GB7 1-1-2-0 / 1-1-1-3 / / 16D

[0080] Step S300C: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric C.

[0081] In the production method of a partially single-layer warp-knitted textured fabric according to this invention, firstly, the production process of the partially single-layer warp-knitted textured fabric can be individually and specifically adjusted and controlled in the warping steps of the warping machine, the weaving steps of the double-needle bed grooved needle warp knitting machine without jacquard, and the finishing and dyeing steps (such as production process parameters). For example, in the warping steps of the warping machine, the number of warping heads and the number of head patterns of each guide bar can be calculated to ensure the consistency and quality of the finished product. At the same time, the overall production method can reduce errors and waste in the production process. Moreover, through the pre-setting, dyeing, and post-setting steps, the hand feel, color uniformity, and dimensional stability of the fabric can be improved, the appearance quality and performance of the finished product can be improved, and the production efficiency and fabric yield can be increased. In addition, the warp-knitted textured fabric includes concave structural units and convex structural units. The convex structural units include multi-layer spaced fabric parts, and the concave structural units include single-layer fabric parts. At least some of the concave structural units and convex structural units are connected. In this way, by connecting at least some concave structural units and convex structural units, a warp-knitted textured fabric with both single-layer and multi-layer fabric parts can be formed, which enhances the three-dimensionality and visual effect of the fabric, makes the warp-knitted textured fabric more durable and less prone to loosening, improves the safety and practicality of the warp-knitted textured fabric, and meets market demand and market prospects.

[0082] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A method for producing a partially single-layer warp-knitted textured fabric, characterized in that, Includes the following steps: Step S100: Based on the pattern of the warp-knitted embossed fabric, calculate the number of warp heads per guide bar and the number of head patterns per guide bar on a double needle bed warp knitting machine without jacquard, and then warp the fabric on the warping machine. Step S200: Weaving on a double-needle bed grooved warp knitting machine without jacquard, multiple concave structural units and multiple convex structural units are formed along the weaving direction of the fabric. At least some of the concave structural units and convex structural units are connected. The convex structural units include multiple layers of spaced fabric sections, and the concave structural units include a single layer of fabric section, thereby obtaining a warp-knitted concave-convex fabric greige. Step S300: The warp-knitted textured fabric is pre-shaped, dyed, and post-shaped to form the finished warp-knitted textured fabric. Before step S100, there is also step SF: at least according to the width, number of widths, horizontal density and pattern of the finished warp-knitted textured fabric, select a double-needle bed grooved warp knitting machine without Jacquard, including at least the first guide bar, the second guide bar and the third guide bar, and at least select the machine width, machine number and number of guide bars of the double-needle bed grooved warp knitting machine without Jacquard. In step S200, the multi-layer spacer fabric section includes a first outer layer, a spacer layer, and a second outer layer. The spacer layer is located between the first and second outer layers and connects the first and second outer layers. Each guide bar of the double-needle bed grooved needle warp knitting machine without jacquards threads yarn according to the warp threading rule. All guide bars form a single-layer fabric section by padding yarn on one side of the needle bed. For the multi-layer spacer fabric section, at least one first guide bar knits the first outer layer only on the front needle bed, at least one second guide bar knits the second outer layer only on the rear needle bed, and at least one third guide bar knits the spacer layer by padding yarn on both the front and rear needle beds to connect the first and second outer layers.

2. The method for producing a partially single-layer warp-knitted textured fabric according to claim 1, characterized in that, In step S200, along the fabric width direction, the width of the concave structural unit and the width of the convex structural unit are determined at least by the number of comb passes, the number of transverse needles, the machine number, and the fabric shrinkage rate of the double needle bed groove needle warp knitting machine without Jacquard.

3. The method for producing a partially single-layer warp-knitted textured fabric according to claim 2, characterized in that, In step S200, along the weaving direction of the fabric, the length of the concave structural unit is determined by the number of rows in which all guide bars form loops on a single needle bed, the weaving density, and the longitudinal shrinkage of the fabric; the length of the convex structural unit is determined at least by the number of rows in which the corresponding guide bars form loops with padding yarn on both the front and back needle beds, the weaving density, and the longitudinal shrinkage of the fabric.

4. A partially single-layer warp-knitted textured fabric produced by the production method according to any one of claims 1-3, characterized in that, include: Concave structural unit and convex structural unit; the concave structural unit includes a single-layer fabric part, and the convex structural unit includes a multi-layer spacer fabric part. The multi-layer spacer fabric part includes a first surface layer, a spacer layer and a second surface layer. The spacer layer is located between the first surface layer and the second surface layer and connects the first surface layer and the second surface layer. At least some concave structural units and convex structural units are connected.

5. The partially single-layer warp-knitted textured fabric according to claim 4, wherein the thickness of the spacer layer ranges from 1.2mm to 800mm along the thickness direction of the fabric, the spacer layer includes spacer yarns, and the spacer yarns are made of 20D-400D yarns; the raw material of the first surface layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn, and the raw material of the second surface layer is one or more of polyester, nylon, polyester-spandex core-spun yarn, and nylon-spandex core-spun yarn.

6. The partially single-layer warp-knitted textured fabric according to claim 5, characterized in that, There are multiple concave structural units and multiple convex structural units. Along the thickness direction of the fabric, the thicknesses of the multiple concave structural units are not exactly the same, and the thicknesses of the multiple convex structural units are not exactly the same.

Images