Protective check fabric and manufacturing method thereof

Abstract

A protective lattice fabric is formed by mutually weaving warp yarns and weft yarns and comprises a surface layer and a bottom layer, the surface layer is located on the surface of the fabric and comprises a reinforcing area, the reinforcing area is formed by weaving first warp yarns and first weft yarns to form a protective surface layer, the protective surface layer comprises a plurality of protective lattices so as to improve the protective performance of the fabric, and the bottom layer is located below the surface layer. The fabric is formed by mutually weaving the second warp yarns and the second weft yarns, so that the layering sense of the fabric is improved, the surface layer and the bottom layer are lifted by the second warp yarns and are interwoven with the first weft yarns to form knots, and the fabric has high strength, high wear resistance and good air permeability and can cope with harsh environment challenges.

Description

Technical Field

[0001] The present invention relates to a protective grid fabric and a manufacturing method thereof, belonging to the technical field of textiles. Background Art

[0002] With the continuous development of textile technology, consumers' requirements for fabric performance are increasing day by day. Especially in the fields of professional sports, outdoor exploration, and industrial protection, fabrics need to have high strength, high wear resistance, and good breathability to meet the challenges of harsh environments. However, traditional woven fabrics have obvious deficiencies in these key performance indicators.

[0003] Specifically, the tensile strength and tear resistance of traditional woven fabrics are difficult to meet the needs of high-intensity activities. They are easily damaged under long-term friction or external forces, affecting their durability and protective efficacy. At the same time, the breathability of traditional fabrics is poor, unable to effectively discharge the heat and moisture generated by the human body, resulting in discomfort for users during exercise or work, and thus affecting performance and efficiency. In addition, the design of traditional woven fabrics is relatively single, lacking layering and personalized design, and it is difficult to meet the diverse needs of different consumers for product functions and appearances. In modern applications, the upper of outdoor sports shoes usually needs to have excellent protective performance to adapt to complex terrains and harsh weather, while providing a comfortable wearing experience. Traditional fabrics are difficult to meet these diverse needs simultaneously. Summary of the Invention

[0004] Aiming at the deficiencies of the existing technology, the purpose of the present invention is to provide a protective grid fabric and a manufacturing method thereof to solve the technical problems of insufficient strength, wear resistance, and breathability of the existing fabrics.

[0005] To achieve the above purpose, the present invention is realized through the following technical solutions: A protective grid fabric and a manufacturing method thereof. The fabric is woven by warp yarns and weft yarns, and it includes: The surface layer, which is located on the surface of the fabric and includes randomly arranged strengthening areas. The strengthening areas are woven by the first warp yarns and the first weft yarns to form a protective layer. The protective layer contains several protective grids to adapt to the protective performance in different environments; the strengthening areas can be single or multiple. The entire upper surface can be covered with strengthening areas, or multiple strengthening areas can be dispersed. When there are multiple strengthening areas, the positional relationship between the strengthening areas is also random. They can be set at the toe, the side of the shoe, or on the left and right sides of the shoe, etc.

[0006] The bottom layer, which is located below the surface layer and is woven by the second warp yarns and the second weft yarns; The surface layer and the bottom layer are intertwined and connected through the first weft yarn and the second warp yarn. The second warp yarn is lifted to the position of the surface layer and intertwined with the first weft yarn to form a connection knot, so as to realize the tight connection between the surface layer and the bottom layer. The connection between the surface layer and the bottom layer is completed by the second warp yarn being lifted from the bottom layer to the position of the surface layer and then intertwined with the first weft yarn.

[0007] Furthermore, the first warp yarn and the first weft yarn are woven to form a protective grid to enhance the stability and anti-deformation ability of the fabric; preferably, the shape of the protective grid can be hexagonal; traditional protective layers often use core-spun yarns, TPU and other hot-melt materials closely intertwined. Although they have high strength, they will significantly increase the weight and hardness of the fabric, affecting the comfort and flexibility of wearing. However, due to its excellent mechanical properties, the protective grid of this application can evenly disperse external forces, not only providing excellent protective performance in key areas, but also reducing the use of materials through precise local strengthening, achieving material savings, while maintaining the breathability and flexibility of the fabric, ensuring the wearing experience of the user.

[0008] Furthermore, the breaking strength of the first warp yarn and the first weft yarn is greater than that of the second warp yarn and the second weft yarn.

[0009] Furthermore, the first warp yarn and the first weft yarn are yarns with a breaking strength ≥ 2 cn / detx, a breaking elongation ≥ 65%, and a yarn diameter ≥ 0.3 mm. This yarn diameter is the key to the thickness of the protective grid to better protect the bottom layer and achieve the protective function.

[0010] Furthermore, the floating length of the second weft yarn is greater than that of the first weft yarn. The floating length refers to the length of the floating line formed when the warp yarn and the weft yarn are intertwined, that is, the length of the warp yarn or the weft yarn continuously emerging on the surface of the fabric. Since the first weft yarn usually uses high-strength materials (such as core-spun yarns, TPU, etc.), although these materials provide excellent protective performance, the hand feeling is relatively poor. In this way, without sacrificing the protective performance, the comfort of the fabric can be significantly improved. Therefore, when the floating line of the first weft yarn is located between the floating lines of two second weft yarns, the covering effect reaches the best, which can not only effectively improve the touch of the fabric, but also enhance the skin-friendly property of the bottom layer and the overall wearing comfort.

[0011] Furthermore, the size of the protective grid can be adjusted by controlling the spacing of the first weft yarn interweaving, adjusting the length of the first warp yarn, or adjusting the weaving density and weaving process between the warp yarn and the weft yarn to meet different protection and design requirements.

[0012] Furthermore, the first warp yarn and the first weft yarn are one of core-spun yarns and TPU. The above materials are preferred materials, but are not limited to core-spun yarns and TPU, as long as the breaking strength ≥ 2 cn / detx and is greater than that of the second warp yarn and the second weft yarn.

[0013] Further, the fabric further includes a through-hole area located at any arbitrary position of the fabric. A plurality of weft yarns are bundled together by rotating and entangling the first warp yarn thick needles with the second warp yarn to form through-holes, and the edges of the through-hole area are reinforced to meet different ventilation requirements.

[0014] Further, the through-hole area includes a first through-hole area and a third through-hole area respectively located on the left and right sides of the shoe upper, and a second through-hole area located at the top of the shoe upper. The through-hole area may include one, two or more of the first through-hole area, the second through-hole area, and the third through-hole area.

[0015] Further, the surface layer further includes a non-reinforced area. The non-reinforced area is woven with the first warp yarn, the second warp yarn and the weft yarn, and a plain weave is used to provide the basic structure and comfort of the fabric. Here, the weft yarn refers to the general term of the first weft yarn and the second weft yarn.

[0016] A manufacturing method of a protective grid fabric includes the following steps: S1. Set parameters: According to the requirements of the pattern parameters, select the appropriate yarn specifications and weaving processes for the surface layer and the bottom layer, and place the warp yarns and weft yarns into the weft accumulators and beam heads in sequence. S2. Weave the initial product: In the surface layer, use the first warp yarn and the first weft yarn to make a protective grid through a hollow leno weave, and the second weft yarn weaves a texture in the bottom layer with the second warp yarn. Locally, a plurality of weft yarns are bundled together by rotating and entangling the first warp yarn thick needles with the second warp yarn to form through-holes. S3. High-temperature pretreatment: Perform high-temperature pre-shrinking and shaping treatment on the woven initial product at 150-180 °C for 10-15 minutes to make the whole piece more flat and dimensionally stable, and reduce the deformation risk in subsequent processing. During the treatment process, appropriate tension needs to be maintained and the humidity of the treatment environment is adjusted according to the characteristics of the yarns. S4. Produce the finished product: According to the design requirements of the shoe upper, design the film negative for the pattern and cut the pieces. After ensuring that the size and shape of each piece meet the design of the shoe upper, laser process the shoe upper, and perform quality inspection on the finished product to ensure that it meets the design requirements and performance standards.

[0017] Further, the first warp yarn is partially turned to the back of the first weft yarn through a leno weave, and a protective grid is formed by the interweaving of the first warp yarn and the first weft yarn.

[0018] Further, the bottom surface is woven with the second warp yarn, the first weft yarn and the second weft yarn. By controlling the float length of the second weft yarn to be greater than the float length of the first weft yarn, the comfort of the bottom layer is improved.

[0019] The beneficial effects of the present invention are: 1. By locally using high-strength yarns to weave a reinforced grid-shaped protective layer on the surface layer, the strength and wear resistance of the fabric are significantly improved, enabling it to better cope with high-intensity usage environments. Moreover, the inside of the reinforcement area consists of several protective grids that can adjust their sizes by controlling the interweaving spacing of the first weft yarns and the lengths of the first warp yarns to adapt to the protection requirements in different environments, providing more flexible and precise protection performance.

[0020] 2. The surface layer is woven with the first warp yarns and the first weft yarns, and the bottom layer is woven with the second warp yarns and the second weft yarns, increasing the layering of the fabric. Also, combined with the design of the through-hole area, the air permeability of the fabric is increased.

[0021] 3. The bottom layer covers the first weft yarn through the floating long lines of the second weft yarn, alleviating the influence of the first weft yarn on the feel and comfort of the bottom layer, and enhancing the skin-friendly property and usage experience of the bottom layer.

[0022] 4. The edges of the through-hole area are reinforced to prevent the fabric from tearing during use, ensuring the stability and durability of the through-holes. The reinforcement areas are randomly distributed on the surface of the surface layer, reasonably enhancing the protection performance of the fabric while not affecting the overall flexibility and comfort of the fabric. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Other features, objectives, and advantages of the present invention will become more apparent by reading the detailed description of the non-limiting embodiments with reference to the following drawings: Figure 1 It is a partial structural cross-sectional schematic diagram of a protective grid fabric of the present invention; Figure 2 It is a schematic diagram of the weaving structure of the colored yarns and high-strength yarns locally interwoven with the warp yarns in the present invention; Figure 3 It is a schematic diagram of the structure formed by the through-holes in the present invention; Figure 4 It is a schematic diagram of the weaving structure formed by the protective grids in the present invention; Figure 5 It is a schematic diagram of the front structure of the physical object of the fabric in the present invention; Figure 6 It is a schematic diagram of the back structure of the physical object of the fabric in the present invention; Figure 7 It is a schematic diagram of the process structure of a manufacturing method of a protective grid fabric of the present invention; Figure 8 For Figure 7 It is a schematic diagram of the refined process structure of step S2 in

[0024] The reference numerals are respectively: 1, surface layer; 101, first warp yarn; 102, first weft yarn; 2, bottom layer; 201, second warp yarn; 202, second weft yarn; 3, through-hole area; 301, first through-hole area; 302, second through-hole area; 303, third through-hole area; 304, through-hole; 4, strengthening area; 401, protection grid. Detailed implementation manners

[0025] In order to make the technical means, creative features, achieved purposes and functions of the present invention easy to understand, the present invention will be further described below in conjunction with specific implementation manners.

[0026] [A protection grid fabric according to the present invention] As Figure 1 , Figure 2 and Figure 3 shown, the present invention provides a technical solution for a protection grid fabric: the fabric is tightly woven by warp yarns and weft yarns, and it includes: A surface layer 1, the surface layer 1 is located on the surface of the fabric and includes randomly arranged strengthening areas 4. The strengthening areas 4 are woven with the first warp yarn 101 and the first weft yarn 102 to form a protection layer. The protection layer contains a number of protection grids to adapt to the protection performance in different environments. Conventional protection layers often use melt-bonding materials such as core-spun yarns and TPU to be tightly interwoven. Although they have high strength, they will significantly increase the weight and hardness of the fabric, affecting the comfort and flexibility of wearing. However, due to the excellent mechanical properties of the protection grids in this application, they can evenly disperse external forces. They can not only provide excellent protection performance in key areas, but also reduce the use of materials through precise local strengthening, achieving material savings. At the same time, they also maintain the breathability and flexibility of the fabric, ensuring the wearing experience of the user.

[0027] A bottom layer 2, the bottom layer 2 is located below the surface layer 1 and is woven by the second warp yarn 201 and the second weft yarn 202; The surface layer 1 and the bottom layer 2 are intertwined and connected through the first weft yarn 102 and the second warp yarn 201. The second warp yarn 201 is lifted to the height of the surface layer 1 and intertwined with the first weft yarn 102 to form a knot, so as to realize the tight connection between the surface layer and the bottom layer. The connection between the surface layer and the bottom layer is completed by lifting the second warp yarn from the bottom layer to the surface layer position and then intertwining it with the first weft yarn, thus completing the connection and combination of the surface layer 1 and the bottom layer 3.

[0028] To enhance the stability of the protective grid, the first warp yarn 101 and the first weft yarn 102 are woven to form a hexagonal protective grid 401, so as to enhance the stability and anti-deformation ability of the fabric. Traditional protective layers often use heat-melt materials such as core-spun yarns and TPU to be tightly interwoven. Although they have high strength, they will significantly increase the weight and hardness of the fabric, affecting the comfort and flexibility of wearing. However, due to its excellent mechanical properties, the protective grid of this application can evenly disperse external forces, not only providing excellent protective performance in key areas, but also reducing the use of materials through precise local strengthening, achieving material savings, while also maintaining the breathability and flexibility of the fabric, ensuring the wearing experience of users.

[0029] To improve the overall protective performance, the breaking strength of the first warp yarn 101 and the first weft yarn 102 is greater than that of the second warp yarn 201 and the second weft yarn 202.

[0030] To enhance the stability and anti-deformation ability, the first warp yarn 101 and the first weft yarn 102 are yarns with a breaking strength ≥ 2 cn / detx, a breaking elongation ≥ 65%, and a yarn diameter ≥ 0.3 mm. This yarn diameter is the key to achieving the thickness of the protective grid, so as to better protect the underlying layer and achieve the protective function.

[0031] To improve the comfort and skin-friendliness, the float length of the second weft yarn 202 is greater than that of the first weft yarn 102. The float length refers to the length of the floating line formed when the warp yarn and the weft yarn are interwoven, that is, the length of the warp yarn or the weft yarn continuously emerging on the fabric surface. Since the first weft yarn 102 usually uses high-strength materials such as core-spun yarns and TPU, although these materials provide excellent protective performance, their handfeel is relatively poor. In this way, without sacrificing the protective performance, the comfort of the fabric can be significantly improved. Therefore, when the floating line of the first weft yarn 102 is located between the floating lines of the two second weft yarns 202, the covering effect is the best, which can not only effectively improve the touch of the fabric, but also enhance the skin-friendliness of the underlying layer and the overall wearing comfort.

[0032] To flexibly adapt to different requirements, the size of the protective grid 401 can be adjusted by controlling the spacing of the first weft yarn 102 interwoven, adjusting the length of the first warp yarn 101, or adjusting the weaving density and weaving process between the warp yarn and the weft yarn, so as to adapt to different protective and design requirements.

[0033] To optimize the material selection, the first warp yarn 101 and the first weft yarn 102 are one of core-spun yarns and TPU. The above materials are preferred materials, but not limited to core-spun yarns and TPU, as long as the breaking strength ≥ 2 cn / detx and is greater than that of the second warp yarn 201 and the second weft yarn 202.

[0034] To meet different breathability requirements, the fabric further includes a through-hole area 3, which is located at any arbitrary position of the local fabric. Multiple weft yarns are bundled together by the thick needles of the first warp yarn 101 rotating and twisting the second warp yarn 201 to form through-holes 304. The edges of the through-hole area 3 are reinforced to meet different breathability requirements.

[0035] To enhance breathability, the through-hole area 3 includes a first through-hole area 301 and a third through-hole area 303 located on the left and right sides of the shoe upper respectively, and a second through-hole area 302 located at the top of the shoe upper. The through-hole area 3 can include one, two or more of the first through-hole area 301, the second through-hole area 302, and the third through-hole area 303.

[0036] To provide the basic structure and comfort, the surface layer 1 further includes a non-reinforced area. The non-reinforced area is woven with the first warp yarn 101, the second warp yarn 201 and the weft yarn by a plain weave to provide the basic structure and comfort of the fabric. Here, the weft yarn refers to the general term of the first weft yarn 102 and the second weft yarn 202.

[0037] Embodiment 1: Figure 5 and Figure 6 FIG. is a schematic diagram of the physical structure of a protective grid fabric of the present invention. In this application, the first warp yarn 101 and the first weft yarn 102 are used in the surface layer 1, and the protective grid 401 is woven by the openwork leno weave of the first warp yarn 101. The size of the protective grid 401 can be adjusted according to the spacing of the weft yarn interweaving. In the bottom layer 2, the second warp yarn 201 and the second weft yarn 202 are woven to form a complex plain weave pattern texture, making it rich in layers.

[0038] In this application, the specific shape of the variable protective grid 401 is a hexagon. In terms of mechanical properties, the symmetry and uniformity of the hexagonal structure can enable the force to be evenly distributed, thereby enhancing the stability and anti-deformation ability of the fabric. At the same time, it performs outstandingly in terms of high strength and high wear resistance, effectively resisting external friction and pulling, and extending the service life of the fabric. Its design can achieve the size change of the protective grid by adjusting the interweaving spacing of the first weft yarn 101, the length of the first warp yarn 102, or the weaving density and weaving process between the warp yarn and the weft yarn, providing precise protective performance according to the use environment and requirements, and being able to perform local strengthening in specific areas, taking into account breathability and flexibility. In addition, the hexagonal structure can make full use of existing equipment and technology to achieve efficient and stable production, and its size, shape and arrangement can be flexibly adjusted according to design requirements.

[0039] The protective cells 401 in Embodiment 1 are smaller protective cells or larger protective cells arranged regularly. Different-sized protective cells 401 can be selected according to the actual use environment. In an environment with more sharp gravel, the protective cells 401 are designed to be smaller and evenly distributed, which can effectively protect the fabric from being penetrated by sharp gravel. Such evenly distributed small protective cells 401 can provide a higher density of protection, ensuring the durability and reliability of the fabric in a harsh environment. Moreover, the evenly distributed protective cells 401 can also maintain the overall strength and stability of the fabric, avoiding damage caused by insufficient local protection. For areas that need key protection, a gradient design of the protective cells 401 can be adopted. Small protective cells 401 are set in the key protection area and then gradually transition to other areas, forming a gradient of protective cells 401 from small to large. This design can not only meet the high-strength protection requirements of key areas but also provide appropriate protection in other areas, thereby optimizing the overall performance of the fabric.

[0040] Embodiment 2: The difference between Embodiment 2 and Embodiment 1 is that the sizes of the protective cells 401 are distributed irregularly, and protective cells 401 of different sizes can be flexibly set according to actual design requirements, taking into account the aesthetic requirements of design while providing protection. This design flexibility enables the fabric to adapt to more diverse application scenarios and aesthetic requirements. For example, larger protective cells are set in areas that require high-strength protection, while smaller protective cells are set in areas that require a higher density of protection. The irregularly distributed protective cells can not only provide excellent protection performance but also meet personalized design needs. By adjusting the size and distribution of the protective cells, unique patterns and textures can be formed on the fabric, enhancing the market attractiveness of the product. In addition, this design can also optimize the breathability and flexibility of the fabric, ensuring comfort and lightness while providing high-strength protection.

[0041] Embodiment 3: In this application, the second weft yarn 202 achieves different covering effects on the first weft yarn 102 by controlling the float length: when the float length of the second weft yarn 202 is slightly greater than that of the first weft yarn 102, the covering effect begins to appear, but the effect is not significant enough. As the float length of the second weft yarn 202 increases, the covering effect gradually enhances until the float length of the second weft yarn 202 reaches an optimal value, at which point the covering effect is the best, and at this time the first weft yarn 102 is almost completely covered, and the comfort and skin-friendly property of the fabric are significantly improved.

[0042] Embodiment 4: Example 4 is an extension of Example 3, further discussing the influence of different lengths of colored yarn floats on the covering effect, and determining the optimal length of colored yarn floats: when the length of the colored yarn float is short, the covering effect is poor, and the high-strength materials of the first weft yarn 102, such as core-spun yarn and TPU, may be significantly exposed, affecting the comfort of the fabric; when the length of the colored yarn float is moderate, the covering effect gradually appears, but it is still not sufficient to completely cover the first weft yarn 102; when the length of the colored yarn float is long, the covering effect is significantly enhanced, but it may cause a slight decrease in the breathability and flexibility of the fabric. Through experiments and tests, it is determined that when the length of the colored yarn float is set to 1.5 times the length of the float of the first weft yarn 102, the covering effect is the best. Under this setting, the colored yarn can effectively cover the first weft yarn 102 while maintaining the breathability and flexibility of the fabric.

[0043] Example 5: The breaking strength of the first warp yarn 101 and the first weft yarn 102 of this application is greater than that of the second warp yarn 201 and the second weft yarn 202. Preferably, the first warp yarn 101 and the first weft yarn 102 are yarns with a breaking strength ≥ 2 cn / detx, a breaking elongation ≥ 65%, and a yarn diameter ≥ 0.3 mm. Preferably, the first warp yarn 101 and the first weft yarn 102 are one of core-spun yarn and TPU.

[0044] Wear resistance tests were carried out on fabrics woven with core-spun yarn or TPU to form the protective grid 401 and fabrics woven with ordinary yarns. The abrasion resistance was detected using a Martindale abrasion tester. To simulate an environment that requires high protection performance, a 400-mesh sandpaper was used for the abrasion test. The specific steps are as follows: S1. Cut specimens from the fabrics woven with core-spun yarn or TPU and the fabrics woven with ordinary yarns, and place them in an environment of constant temperature and humidity of 20 ± 2 °C and 65 ± 5 °C for more than 8 hours to ensure the consistency of the test conditions; S2. Cut a specimen from a flat part of the specimen; S3. Remove the load and the load shaft rod from the testing machine; S4. Remove the top plate and the test fixture; S5. Installation of the specimen: Loosen the fixing ring on the test fixture, remove the specimen pressing plate, place the specimen in the base of the test fixture, place a specimen spacer between the specimen and the base of the test fixture, then place the specimen pressing plate on the specimen spacer and fix it with the fixing ring; S6. Installation of the wool felt and the sandpaper: Loosen the fixing screw and the fixing ring, place the wool felt on the base and then lay a 400-mesh sandpaper on it. Press a 2.5 KG pressure plate in the center of the sandpaper. After ensuring that the sandpaper is flat and firmly fixed, install the fixing ring and lock the fixing screw; S7. Install the top plate back, and pass the load shaft rod (9 KPA) through the round hole of the top plate; S8. Place the test fixture with the specimen face - down on the base fixture. Adjust the circular groove of the test fixture to align with the load shaft rod so that the load shaft rod inserts into the circular groove of the test fixture. S9. Start the switch according to the standard set number of times to start the test, and it will automatically stop after reaching the set number of times.

[0045] The test results are as follows: In the abrasion resistance test, the fabric using high - strength yarns showed significant performance advantages. Specifically, the fabric of high - strength yarns reached 60 Cycles in the Martindale abrasion resistance test, compared with only 35 Cycles for the ordinary colored yarn fabric, showing its excellent abrasion resistance. In addition, the abrasion area of the high - strength yarn fabric was significantly reduced, and the mass loss was also greatly reduced, indicating less material loss during the abrasion process. In terms of color change, the ΔE value of the high - strength yarn fabric was only 1.2, much lower than 3.5 of the ordinary colored yarn, indicating less impact on the appearance during the abrasion process. In summary, the first warp yarn 101 and the first weft yarn 102 in this application, by using core - spun yarns, TPU and other yarns with a breaking strength greater than that of the second warp yarn 201 and the second weft yarn 202, and a breaking strength ≥2 cn / detx, a breaking elongation ≥65%, and a yarn diameter ≥0.3 mm, significantly improved the abrasion strength of the fabric and can effectively achieve good protective performance.

[0046] Example 6: In the fabric of this application, a through - hole area 3 is made at any arbitrary local position. The through - hole 304 is formed by the first warp yarn 101 rotating and thick - needle - holding the second warp yarn 201 to bundle multiple weft yarns together, which is used to increase the breathability of the fabric.

[0047] The edge of the through - hole area 3 of this application is reinforced to prevent the fabric from tearing during use, ensuring the stability and durability of the through - hole 304. The strengthening areas 4 are randomly distributed on the surface of the surface layer 1, reasonably enhancing the protective performance of the fabric without affecting the overall flexibility and comfort of the fabric.

[0048] The fabric produced by this application is particularly suitable for manufacturing various types of shoe uppers such as sports shoes, casual shoes, and outdoor shoes. It can provide high strength, high abrasion resistance, and good breathability, and at the same time has a unique aesthetic effect, improving the quality and market competitiveness of footwear products.

[0049] Example 7: In the fabric of the present application, non-reinforced areas are provided at arbitrary positions in the local area of the surface layer 1. The non-reinforced areas are woven with warp and weft yarns, specifically using a plain weave or twill weave to ensure the stability and comfort of its basic structure. Among them, softer yarns such as cotton yarn or polyester fiber can be used in the non-reinforced areas to enhance the comfort of the fabric. Also, according to specific requirements, yarns of different colors or materials can be selected to achieve rich visual effects and layering.

[0050] [Manufacturing method of a protective grid fabric according to the present invention] As Figure 7 and Figure 8 shown, in order to facilitate the production of this fabric, the present invention also provides a manufacturing method of a protective grid fabric, which includes the following steps: S1. Set parameters: According to the requirements of the pattern parameters, select appropriate yarn specifications and weaving processes for the surface layer 1 and the bottom layer 2, and place the warp and weft yarns in the weft accumulator and beam in sequence; S2. Weave the initial product: Make protective grids on the surface layer 1 using the first warp 101 and the first weft 102 through the openwork leno weave, weave textures on the bottom layer with the second weft 201 and the second warp 202, and locally twist the second warp 201 with the thick needle of the first warp 101 to bundle multiple weft yarns together to form through holes 304; S3. High-temperature pretreatment: Perform high-temperature pre-shrinking and setting treatment on the woven initial product to make the whole piece more flat and dimensionally stable, reducing the risk of deformation in subsequent processing.

[0051] Further, the first warp 101 is partially turned to the back of the first weft 102 through the leno weave, and a protective grid is formed by the interweaving of the first warp 101 and the first weft 102.

[0052] Further, it is woven with the second warp 201 and the first weft 102 and the second weft 202. By controlling the float length of the second weft 202 to be greater than that of the first weft 102, the comfort of the bottom layer is improved.

[0053] During the process of weaving the initial product in the present application, the machine operates automatically according to a preset program. In the order from bottom to top, the weft yarns are sequentially interwoven with the warp yarns to gradually weave an initial product with a width of 160 CM for the whole piece. During this process, various parameters of the loom are precisely controlled. For example, the tension of the weft yarn needs to be kept stable and moderate to ensure tight but not overly rigid interweaving, and the interweaving density should be reasonably set according to the design requirements to ensure that the fabric has both high strength and good air permeability.

[0054] In the surface layer 1 of the present application, the strengthening area 4 is woven with the first warp yarn 101 and the first weft yarn 102. The first warp yarn 101 is led out from the warp beam of the loom, intersects with the first weft yarn 102 at the reed seat of the loom, and the weft yarn is beaten in by the beating-up mechanism of the loom to form a tight and high-strength woven structure; the non-strengthening area is woven with the upper warp yarn 101 and the colored yarn 103. According to the requirements of the design pattern, the colored yarn 103 is accurately selected and introduced into the weaving process by the weft selector mechanism of the loom at specific positions, and intersects with the first warp yarn 101 to produce rich colors and patterns.

[0055] In the present application, the second warp yarn 201 and the second weft yarn 202 are selected for the weaving of the bottom layer 2. The second warp yarn 201 is also led out from the warp beam, and intersects with the second weft yarn 203 in another weaving area of the loom to construct a complex and delicate plain weave pattern texture. The dobby mechanism or jacquard mechanism of the loom accurately controls the lifting and intersecting actions of the second warp yarn 201 according to the design pattern, so that the pattern of the bottom layer is perfectly presented in the interlacing of the warp and weft yarns.

[0056] In the through-hole area 3 of the present application, a specific mechanism of the loom rotates the thick needle of the first warp yarn 101 to accurately twist the second warp yarn 201. During this process, multiple weft yarns are cleverly bundled together, thereby forming breathable and unique through-holes 304 on the fabric. The size and distribution density of the through-holes 304 are accurately controlled through the parameter adjustment of the loom and the interaction between the first warp yarn 101 and the second warp yarn 201 to meet the breathable requirements of different areas.

[0057] The entire weaving process combines advanced design software, efficient looms and precise post-processing equipment, ensuring the high quality and high performance of the fabric. Through precise process control and equipment operation, the finally produced fabric not only has excellent protective performance, but also has rich layering and good breathability.

[0058] The above shows and describes the basic principles, main features and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to encompass all changes falling within the meaning and scope of the equivalent elements of the claims in the present invention. Any reference signs in the claims should not be regarded as limiting the claims involved.

[0059] In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment contains only an independent technical solution. This narrative style of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A protective grid fabric, characterized in that: The fabric is woven by warp yarns and weft yarns, and it includes: A surface layer (1), the surface layer (1) is located on the surface of the fabric and includes a strengthening area (4), the strengthening area (4) is woven by a first warp yarn (101) and a first weft yarn (102) to form a protective layer, and the protective layer contains a number of protective cells; A bottom layer (2), the bottom layer (2) is located below the surface layer (1) and is woven by a second warp yarn (201) and a second weft yarn (202); The surface layer (1) and the bottom layer (2) are intertwined and connected through the first weft yarn (102) and the second warp yarn (201), and the second warp yarn (201) is lifted to the position of the surface layer (1) and intertwined with the first weft yarn (102) to form a knot, so as to realize the tight connection between the surface layer and the bottom layer.

2. The protective grid fabric according to claim 1, wherein: The first warp yarn (101) and the first weft yarn (102) are woven to form a protective cell (401).

3. A protective grid fabric according to claim 1, characterized in that: The breaking strength of the first warp yarn (101) and the first weft yarn (102) is greater than that of the second warp yarn (201) and the second weft yarn (202).

4. The protective grid fabric according to claim 3, characterized in that: The first warp yarn (101) and the first weft yarn (102) are yarns with a breaking strength ≥ 2 cn / detx, a breaking elongation ≥ 65%, and a yarn diameter ≥ 0.3 mm.

5. A protective grid fabric according to claim 1, characterized in that: The floating length of the second weft yarn (202) is greater than the floating length of the first weft yarn (102).

6. The protective grid fabric according to claim 1, characterized in that: The size of the protective cell (401) can be adjusted by controlling the spacing of the first weft yarn (102) intertwined, adjusting the length of the first warp yarn (101), or adjusting the weaving density and weaving process between the warp yarns and the weft yarns.

7. A protective grid fabric according to claim 1, characterized in that: The first warp yarn (101) and the first weft yarn (102) are one of core-spun yarns and TPU.

8. A protective grid fabric according to claim 1, characterized in that: The fabric further includes a perforated area (3), the perforated area (3) is located at any position of the fabric locally, and a plurality of weft yarns are bundled by the first warp yarn (101) rotating thick needles to catch the second warp yarn (201) to form a through hole (304), and the edge of the perforated area (3) is reinforced.

9. A protective grid fabric according to claim 8, characterized in that: The perforated area (3) includes a first perforated area (301) and a third perforated area (303) located on the left and right sides of the shoe upper respectively, and a second perforated area (302) located at the top of the shoe upper.

10. A protective grid fabric according to claim 1, characterized in that: The surface layer (1) further includes a non-strengthening area, and the non-strengthening area is woven by the first warp yarn (101), the second warp yarn (201) and the weft yarn, and the plain weave is used to provide the basic structure and comfort of the fabric.

11. A manufacturing method of a protective grid fabric, characterized in that: It includes the following steps: S1. Set parameters: According to the requirements of the pattern parameters, confirm the specifications of the yarns used according to the weaving processes of the surface layer (1) and the bottom layer (2), and distinguish the warp yarns and the weft yarns of the yarns and place them in the weft accumulators and beam heads; S2. Weave the initial product: Make protective cells on the surface layer (1) by using the first warp yarn (101) and the first weft yarn (102) through the leno weave, weave the texture on the bottom layer with the second weft yarn (201) and the second warp yarn (202), and locally bundle a plurality of weft yarns by the first warp yarn (101) rotating thick needles to catch the second warp yarn (201) to form a through hole (304); S3. High-temperature pretreatment: The initially woven product is subjected to high-temperature pre-shrinking and shaping treatment to make the whole piece more flat and dimensionally stable, reducing the risk of deformation in subsequent processing.

12. A manufacturing method of a protective grid fabric, characterized in that: The first warp yarn (101) is partially turned to the back of the first weft yarn (102) through the leno weave, and a protective grid is formed by the interweaving of the first warp yarn (101) and the first weft yarn (102).

13. A protective grid fabric according to claim 11, wherein, It is woven using the second warp yarn (201), the first weft yarn (102), and the second weft yarn (202). By controlling the floating length of the second weft yarn (202) to be greater than that of the first weft yarn (102), the comfort of the bottom layer is improved.

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