Filling three-dimensional fabric weaving method and filling three-dimensional fabric

Abstract

The invention provides a weaving method of a filled three-dimensional fabric and the filled three-dimensional fabric. The weaving method comprises a weaving step of weaving a middle layer between a fabric surface layer and a fabric bottom layer: controlling yarns of the middle layer to be alternately woven between double needle beds to form a first woven structure of a three-dimensional supporting structure; controlling the yarns of the middle layer to be independently knitted on one needle bed of the double-needle bed to form a second knitted structure; the first weaving structure of the middle layer is woven by adopting a double-needle bed, and three-dimensional support is formed; the second knitting structure is knitted through one needle bed in the two needle beds, the yarn filling amount is reduced, and the overall gram weight is reduced; the first woven structures and the second woven structures are alternately arranged and different in structure, so that the stereoscopic impression can be realized without increasing the density or the number of layers of fibers; meanwhile, the second knitting structure is knitted by one of the two needle beds, natural breathable gaps can be formed and cooperate with the three-dimensional structure gaps of the first knitting structure, and the stuffiness problem caused by a high-density structure is solved.

Description

Technical Field

[0001] This invention relates to the field of textile fabrics, and in particular to a weaving method for a filled three-dimensional fabric and the filled three-dimensional fabric itself. Background Technology

[0002] In recent years, with the increasing demand for personalization and comfort among young consumers, 3D filled fabrics have gradually become a research hotspot in the textile industry due to their unique visual and tactile experience. Compared with traditional flat fabrics, 3D fabrics, through the three-dimensional structure formed by differences in fiber shrinkage, can create a rich sense of layering and a fluffy texture, showing broad application potential in clothing, home furnishings, and other fields.

[0003] Existing three-dimensional fabrics achieve their three-dimensional effect primarily through the difference in shrinkage between elastic fibers (such as spandex) and non-elastic fibers (such as cotton and polyester) on a single plane. During the weaving process, these two types of fibers, due to their different heat shrinkage rates, will shrink unevenly after being heated, thus creating textured patterns or a three-dimensional filling effect.

[0004] In traditional processes, to achieve a significant three-dimensional effect, the overall fiber density or number of layers needs to be increased, which leads to an increase in fabric weight and affects comfort; moreover, the high-density fiber structure hinders air circulation, which can easily cause stuffiness, especially in summer or sports scenarios. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a weaving method for a three-dimensional filled fabric and a three-dimensional filled fabric that can achieve a three-dimensional effect while ensuring lightweight and breathability.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for weaving a filled three-dimensional fabric includes a weaving step of weaving an intermediate layer between a fabric surface layer and a bottom layer: The yarns of the intermediate layer are controlled to be knitted alternately between the double needle beds to form the first knitting structure of the three-dimensional support structure; The yarns of the intermediate layer are controlled to be knitted independently on one of the two needle beds, forming a second knitting structure; The first and second weave structures are alternately woven.

[0007] To solve the above-mentioned technical problems, another technical solution adopted by the present invention is as follows: A three-dimensional filled fabric is woven using the three-dimensional filled fabric weaving method described above.

[0008] The beneficial effects of this invention are as follows: It provides a weaving method for a filled three-dimensional fabric and the filled three-dimensional fabric. The first weaving structure of the middle layer adopts double needle bed weaving and forms a three-dimensional support. The second weaving structure is woven through one needle bed of the double needle bed, which reduces the amount of yarn filling and lowers the overall weight. The alternating arrangement and structural differences between the first and second weaving structures can achieve a three-dimensional effect without increasing the fiber density or number of layers. At the same time, the second weaving structure, woven through one needle bed of the double needle bed, can form a natural breathable gap, which works in conjunction with the three-dimensional structural gap of the first weaving structure to build an air circulation channel, solve the stuffiness problem caused by the high-density structure, and achieve a balance of "low weight, high breathability, and strong three-dimensionality". Attached Figure Description

[0009] Figure 1 This is an example flow diagram of a textile process for filling three-dimensional fabric according to an embodiment of the present invention. Figure 2 This invention provides an example of a textile process for the association between the monofilament filling area and the non-filling area in a textile process for filling three-dimensional fabrics. Figure 1 ; Figure 3 This invention provides an example of a textile process for the association between the monofilament filling area and the non-filling area in a textile process for filling three-dimensional fabrics. Figure 2 ; Figure 4 This is an example diagram illustrating the textile process of the association between the multifilament filling area and the non-filling area in a textile process for filling three-dimensional fabric according to an embodiment of the present invention. Figure 5 This is an example diagram of the overall structure of a filled three-dimensional fabric according to an embodiment of the present invention; Figure 6 This is a planar example diagram of an intermediate layer structure of a three-dimensional filled fabric according to an embodiment of the present invention; Figure 7 This is an example diagram of a monofilament filling area of ​​a three-dimensional fabric according to an embodiment of the present invention; Figure 8 This is an example diagram of the multifilament filling area of ​​a three-dimensional fabric according to an embodiment of the present invention; Figure 9 This is a combined example diagram of a monofilament filling area, a multifilament filling area, and a composite filling area in a three-dimensional filling fabric according to an embodiment of the present invention. Label Explanation: 1. Surface layer; 2. Intermediate layer; 21. First braided structure; 211. Monofilament filling area; 212. Multifilament filling area; 213. Composite filling area; 22. Second braided structure; 3. Bottom layer. Detailed Implementation

[0010] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0011] Definitions: Three-dimensional support structure: A three-dimensional support structure refers to the use of yarn material selection and weaving process design to create a three-dimensional structure in the middle layer of the fabric with a certain thickness, strength and shape stability, thereby achieving a combination of support and three-dimensional effect.

[0012] Monofilament: refers to yarn composed of a single continuous fiber, usually with a relatively thick diameter and high rigidity, stiffness and transparency.

[0013] Multifilament: refers to yarn made of multiple continuous fibers (usually dozens to hundreds) twisted or combined. It has a finer diameter and is soft, fluffy, and elastic. Through the synergistic effect of multiple fibers, it combines a certain strength with flexibility, has a delicate feel, and is not easily broken.

[0014] Monofilament and multifilament blending: Monofilaments and multifilaments are combined in the same first knitting structure to form a composite structure that combines the performance advantages of both. During double-needle bed knitting using Jacquard combs, monofilaments and multifilaments are interwoven, stacked, or nested according to a designed ratio or spatial distribution. For example, monofilaments form a basic support skeleton by looping or weft insertion, while multifilaments fill the gaps in the skeleton and cover the surface of the monofilaments, forming a composite structure of "rigid skeleton + flexible filling"; or both can alternately participate in looping at different knitting stages, allowing the stiffness of the monofilaments and the bulkiness of the multifilaments to be uniformly integrated at the microscopic level.

[0015] Loop forming: Loop forming refers to the weaving process in which yarn is hooked, padded, closed, and looped through a series of actions such as needle hooking, padding, and looping. It is a basic technology for constructing fabric structure.

[0016] Weft insertion: Periodically inserting one or more yarns between the main loops and extensions of a warp-knitted fabric.

[0017] Warp feeding from a coil: Warp feeding from a coil refers to a method of feeding yarn (such as multifilament or part monofilament) by pre-winding it onto a coil and releasing the yarn by controlling the rotation of the coil through a mechanical device.

[0018] Yarn beam feeding: Yarn beam feeding refers to placing the yarn (such as multifilament or part monofilament) on the yarn beam and releasing the yarn by adjusting the tension control device of the yarn beam, thus providing the yarn for the weaving process.

[0019] Long cross stitch weave: Long cross stitch weave refers to a weave where the yarn crosses 3 or more stitch lengths to form loops or weft.

[0020] Repeated warp weave: a weave in which each yarn is simultaneously padded on two adjacent needles to form a loop.

[0021] Heavy warp weft weave: This type of weave combines heavy warp weave and weft weave.

[0022] Multi-needle warp plain weave: refers to a warp plain weave pattern in which the yarn crosses more than three needles during weaving.

[0023] Please refer to Figure 1 A method for weaving a filled three-dimensional fabric, comprising the step of weaving an intermediate layer 2 between a fabric surface layer 1 and a bottom layer 3: The yarns of the intermediate layer 2 are controlled to be alternately woven between the double needle beds to form the first weaving structure 21 of the three-dimensional support structure; The yarn of the intermediate layer 2 is controlled to be independently woven on one of the needle beds of the double needle bed to form the second knitting structure 22; The first weave structure 21 and the second weave structure 22 are woven alternately.

[0024] As can be seen from the above description, the beneficial effects of the present invention are as follows: It provides a weaving method for a filled three-dimensional fabric and a filled three-dimensional fabric. The first weaving structure 21 of the intermediate layer 2 adopts double needle bed weaving and forms a three-dimensional support. The second weaving structure 22 is woven through one needle bed of the double needle bed, which reduces the amount of yarn filling and lowers the overall weight. Due to the difference between the first weaving structure 21 and the second weaving structure 22, a three-dimensional effect can be achieved without increasing the fiber density or the number of layers. At the same time, the second weaving structure 22 is woven through one needle bed of the double needle bed, which can form a natural breathable gap. It works in conjunction with the three-dimensional structural gap of the first weaving structure 21 to build an air circulation channel, solve the stuffiness problem caused by the high-density structure, and achieve a balance of "low weight, high breathability, and strong three-dimensionality".

[0025] Furthermore, the first braided structure 21 is woven from monofilaments and / or multifilaments.

[0026] As described above, the first weaving structure 21 employs monofilament, multifilament, or a mixture of both, allowing for flexible adaptation to different functional requirements. Monofilament weaving provides crisp, three-dimensional support, suitable for scenarios requiring structural stability (such as clothing shoulders); multifilament weaving enhances tactile comfort, suitable for scenarios prioritizing softness (such as cushions); and mixed weaving balances support and softness. By combining materials, it addresses the dependence on individual fiber shrinkage differences, reduces reliance on fiber density, and lowers weight while maintaining a three-dimensional effect, thus broadening the fabric's application range. By adjusting the yarn feeding type of the first weaving structure 21, the differences between it and the second weaving structure 22 are further enriched, enabling adaptation to different three-dimensional effects while also meeting functional requirements.

[0027] Furthermore, the monofilament is fed using a coiled head.

[0028] As described above, the stable tension of the warp feed is compatible with monofilament / multifilament raw materials: for monofilaments, it can avoid deformation exposure caused by tension fluctuations, and for multifilaments, it can ensure the uniformity of the loops formed in sequence; at the same time, the stable tension works in conjunction with "alternating weaving" to reduce the tension difference between the first structure and the second structure, thereby reducing fabric wrinkling during the weaving process.

[0029] Furthermore, including: The monofilament is woven between two needle beds using a Jacquard comb in a looping and weft-insertion manner.

[0030] As described above, the monofilament is woven by Jacquard combs between two needle beds using loop forming and weft insertion methods, combined with warp feeding at the head, forming a synergistic effect of "warp feeding at the head + Jacquard loop forming and weft insertion". The alternating loop forming and weft insertion weaving allows the monofilament to form uniform support nodes in the three-dimensional structure, avoiding the problem of monofilament accumulation and heaviness caused by single loop forming in existing technologies; the weft insertion process reduces the amount of yarn used and lowers the weight. At the same time, the jacquard function of the Jacquard comb can precisely control the distribution of monofilaments, and with the stable tension of warp feeding at the head, it ensures that the monofilaments are not exposed, which not only enhances the cushioning and support of the fabric, but also improves the smoothness of the hand feel.

[0031] Furthermore, the weaving of the second weave structure 22 includes: Long-cross stitch weaving is performed on one of the needle beds of the double needle bed using a Jacquard comb.

[0032] As described above, the double-needle bed weft insertion in the first knitting structure 21 generates a certain tension, while the long-cross needle structure of the second knitting structure 22 is knitted through one of the double needle beds, and its tension is close to that of the first structure. This avoids fabric deformation or monofilament exposure caused by tension difference, achieving tension balance between the first knitting structure 21 and the second knitting structure 22. This tension balance design ensures the stability of the weaving process, while the long-cross needle structure in the non-filled areas reduces yarn accumulation, further reducing weight and improving breathability.

[0033] Furthermore, the long cross-needle structure is at least one of the following: heavy warp weft weft structure, heavy warp loop structure, or multi-needle plain warp structure with 3 or more needles.

[0034] As can be seen from the above description, the warp feed of the long cross needle structure is close to that of the monofilament in the first knitting structure in the front and back needle beds in the alternating looping and weft insertion, which can better match the tension of the first knitting structure 21 and meet the requirements of the head warp feed.

[0035] Furthermore, the monofilament is fed using a yarn frame.

[0036] As described above, the warp feed on the yarn frame allows for flexible adjustment of monofilament tension, adapting to the rigidity of the monofilament. Simultaneously, in conjunction with alternating double needle beds, the flexibility of the yarn frame warp feed makes it easier for the monofilament to form a uniform filling area in the three-dimensional structure, avoiding the tension limitations of the coiled warp feed in complex jacquard weaves. This design retains the support of the monofilament while enhancing weaving adaptability, making it particularly suitable for three-dimensional fabrics requiring complex jacquard patterns.

[0037] Furthermore, the monofilament is knitted in loops by Jacquard combs between the double needle beds.

[0038] As described above, the reciprocating looping allows the monofilament to form a continuous three-dimensional support column between the two needle beds, enhancing the thickness and bulkiness of the fabric; the adjustable tension of the yarn beam ensures the stable operation of the monofilament in the reciprocating knitting, avoiding monofilament breakage or structural unevenness caused by sudden tension changes.

[0039] Furthermore, the weaving of the second weave structure 22 includes: Loop knitting is performed using a Jacquard comb on either of the two needle beds.

[0040] As described above, the reciprocating loop tension of the first knitting structure 21 is relatively large, while the single-needle bed loop tension of the second knitting structure 22 is relatively small. The warp feed of the yarn frame can compensate for this difference by dynamically adjusting the tension, thus preventing wrinkles or exposed monofilaments in the fabric due to uneven tension. At the same time, the non-filled area formed by the single-needle bed loop formation reduces the amount of yarn used, further reducing the weight and improving breathability, thus achieving a balance between three-dimensional support and comfortable hand feel in the fabric.

[0041] Furthermore, the multifilament yarn is fed using a yarn feeder.

[0042] As described above, the warp feeder allows for flexible control of the warp feed speed and tension of the multifilament yarn, adapting to its soft characteristics and preventing structural loosening due to excessive stretching during weaving. Simultaneously, combined with alternating double needle beds, the multifilament yarn forms a uniform filling layer within the three-dimensional structure, enhancing the fabric's bulk and elasticity. Compared to existing technologies where improper multifilament warp feed results in heavy or collapsed fabrics, this design fully utilizes the bulky characteristics of the multifilament yarn while ensuring structural stability.

[0043] Furthermore, the multifilaments are woven in loops between two needle beds by Jacquard combs.

[0044] As described above, the multifilament yarns are knitted sequentially in loops between the two needle beds, combined with warp feed on the yarn frame, forming a synergistic structure of "warp feed on the yarn frame + sequential loop formation." Sequential loop formation allows the multifilament yarns to form orderly three-dimensional filling units between the two needle beds, avoiding uneven loft caused by disordered knitting; the tension control of the warp feed on the yarn frame ensures that the multifilament yarns are not overstretched during the loop formation process, preserving their soft and fluffy characteristics.

[0045] Furthermore, the weaving of the second weave structure 22 includes: Loop knitting is performed using a Jacquard comb on either of the two needle beds.

[0046] As described above, the double-needle bed loop-forming tension of the first knitting structure 21 is relatively high, while the single-needle bed loop-forming tension of the second knitting structure 22 is relatively low. The yarn feed can dynamically adjust the tension to prevent fabric deformation. Simultaneously, the non-filled areas formed by the single-needle bed loop-forming have partial openwork, reducing multifilament accumulation, thus reducing fabric weight and improving breathability. This design allows multifilament fabrics to maintain their bulk while solving the problems of poor breathability and high weight in existing technologies.

[0047] Furthermore, it also includes the weaving steps for the bottom layer 3 and the top layer 1: It is woven from at least one of jacquard combs and ground combs, in a plain weave, regular mesh, or jacquard pattern.

[0048] As described above, the top layer 1 and bottom layer 3 are woven with jacquard combs and ground combs using plain weave, regular mesh, or jacquard weave. The plain weave structure ensures the basic stability of the top and bottom layers 3, preventing excessive stretching of the middle layer 2. The regular mesh or jacquard weave increases air permeability, working in conjunction with the gaps in the middle layer 2 to form a continuous air circulation from top layer 1 to middle layer 2 to bottom layer 3, improving overall breathability. The jacquard design also enriches the fabric's appearance, enhances its visual appeal, and achieves a balance between functionality and aesthetics.

[0049] Furthermore, the bottom layer 3 and the top layer 1 employ different weaving methods; One layer is woven in a plain weave, while the other layer is woven in a regular mesh or jacquard pattern.

[0050] As described above, the bottom layer 3 employs different weaving methods (one plain weave, one mesh / jacquard). The plain weave layer provides basic strength to prevent fabric deformation; the mesh / jacquard layer enhances breathability. Together with the alternating structure of the middle layer 2, they form a complementary "stability-breathability-support" function. Compared to the same weave on both sides, this combination further optimizes the functional allocation, allowing the fabric to maintain shape stability while improving breathability, making it more suitable for scenarios requiring both stability and breathability. Furthermore, the weaving of the surface layer 1 or the bottom layer 3 incorporates elastic yarns.

[0051] As described above, the stretch resilience of the elastic yarn, combined with the weaving methods (plain weave / mesh / jacquard) of the face and bottom layers 3, enhances the three-dimensional effect of the fabric. Simultaneously, in conjunction with the three-dimensional support structure of the middle layer 2, it ensures the stability of the middle layer 2's three-dimensional shape while allowing the face and bottom layers 3 to stretch and recover with external forces (such as human movement), reducing the feeling of restriction. This enhances the dynamic adaptability of the fabric on top of the functions of the face and bottom layers 3, broadening its application in sportswear and other scenarios.

[0052] Please refer to Figure 5 A type of three-dimensional filled fabric, which is woven by the weaving method of a three-dimensional filled fabric described above.

[0053] As can be seen from the above description, the beneficial effects of the present invention are as follows: It provides a three-dimensional filled fabric. In the three-layer structure of this fabric, the alternating first and second weave structures 22 of the middle layer 2 create a thickness difference. The three-dimensional support of the first weave structure 21 ensures a significant three-dimensional effect, while the loose characteristics of the second weave structure 22 reduce the overall weight. The diverse weaves of the top and bottom layers 3, combined with the breathable gaps in the middle layer 2, improve air circulation. The fabric combines a striking three-dimensional visual effect, lightweight construction, and high breathability. Furthermore, the stability of the first weave structure 21 avoids the deformation problems of traditional processes, making it suitable for various scenarios where both appearance and comfort are required.

[0054] The present invention discloses a textile process for filling three-dimensional fabric and the filling three-dimensional fabric, which is applicable to scenarios where textile fabrics have requirements for three-dimensional visual / tactile feel, lightweight and breathability, and is especially suitable for fabric production in the fields of clothing and home furnishing.

[0055] Please refer to Figures 1 to 3 Embodiment 1 of the present invention is as follows: For reference Figure 1 A textile process for filling three-dimensional fabrics includes the following steps: In this embodiment, for ease of explanation, the weaving of the outer and bottom layers is described first, followed by the weaving of the middle layer. In other equivalent embodiments, the weaving order of the outer, bottom, and middle layers is not limited and can be adjusted according to actual needs.

[0056] The top layer 1 and the bottom layer 3 are woven by combing.

[0057] In this embodiment, the weave is done using Jacquard combs and / or ground combs to create plain weave, regular mesh, or jacquard patterns. There are two types of jacquard weaving: one is using Jacquard combs to weave patterns, and the other is using Jacquard combs and ground combs to weave mesh patterns. Plain weave / regular mesh patterns are created using ground combs.

[0058] The first knitting structure 21 of the intermediate layer 2 is knitted using at least one of monofilament and multifilament through a jacquard comb, based on a double needle bed; The weave of the first braided structure 21 includes at least one of the following: Using monofilaments through Jacquard combs, the monofilament filling area 211 is woven based on a double needle bed; Multifilament yarns are used through Jacquard combs, and the multifilament filling area 212 is knitted based on a double needle bed; By using jacquard combs, a composite filling area 213 is formed by mixing and weaving monofilament filling area 211 and multifilament filling area 212 based on a double needle bed.

[0059] The second knitting structure 22 of the intermediate layer 2 is knitted using a jacquard comb and one side of the top layer 1 or bottom layer 3 with one of the two needle beds.

[0060] In this embodiment, the first braided structure 21 is implemented as a monofilament filling area 211. The braiding of the monofilament filling area 211 includes: The monofilament filling area 211 is formed by using monofilaments in the Jacquard comb and by knitting in the first and second needle beds through looping and weft insertion.

[0061] Specifically, in this embodiment, the monofilament filling area 211 can be arbitrarily selected from the following two weaving methods and is associated with the second weaving structure 22: (1) Refer to Figure 2 The monofilament filling area 211 is formed by using a Jacquard comb to feed the warp with a monofilament coil, forming loops and weft weaves on the first needle bed and the second needle bed.

[0062] In this implementation, the first Jacquard comb uses monofilament coiled warp feeding, forming loops and weft weaves alternately on the first and second needle beds to form a monofilament filling area 211 with a certain height and thickness, providing good cushioning and support performance. Compared with the reciprocating weave between the first and second needle beds, this structure greatly reduces yarn tension and ensures that the monofilament loops are uniform and flat, preventing them from being squeezed and deformed.

[0063] Correspondingly, the weaving of the second weaving structure 22 includes: The second knitting structure 22 is formed by long-cross stitch knitting on one of the needle beds using Jacquard combs, creating the bottom or top layer knitting portion. The long-cross stitch knitting is at least one of the following: heavy warp-weft weft knitting, heavy warp loop knitting, or multi-needle warp plain knitting with 3 or more stitches.

[0064] The first jacquard comb is knitted in a long-cross stitch structure (which can be a heavy warp weft weft structure, a heavy warp loop structure, or a multi-needle warp plain structure with more than 3 needles) in one of the double needle beds. The tension of this structure is close to the knitting tension of the first jacquard comb in the first knitting structure 21, thereby balancing the tension of the head and forming part of the bottom layer 3 of the second knitting structure 22.

[0065] The difficulty of the warp threading technique lies in the need to combine it with the adjustment of the structure. The tension of the first knitting structure 21 and the second knitting structure 22 must be close to that of the first knitting structure 21 and the second knitting structure 22 for the knitting to be successful. Therefore, the tension of the alternating looping and weft insertion in the two needle beds in the filling area is about the same as the tension of the long cross needle structure knitted in only one needle bed in the second knitting structure 22.

[0066] (2) Refer to Figure 3 The monofilament filling area 211 is formed by the Jacquard comb using a monofilament yarn frame to feed the warp and perform reciprocating loop knitting on the first needle bed and the second needle bed.

[0067] In this embodiment, the first Jacquard comb uses a monofilament yarn frame for warp feeding and performs reciprocating loop knitting on the first needle bed and the second needle bed to form a monofilament filling area 211, which has a certain height and thickness.

[0068] Correspondingly, the weaving of the second weaving structure 22 includes: The bottom or top layer of the second knitting structure 22 is formed by loop knitting using a jacquard comb on either of the double needle beds.

[0069] In this embodiment, the first Jacquard comb is used for loop knitting on the second needle bed. The tension structure of this loop knitting structure differs greatly from the knitting tension of the first Jacquard comb in the first knitting structure 21. The tension is adjusted by the warp feed method on the yarn frame to form part of the bottom layer 3 of the second knitting structure 22. The difficulty of the warp feed method on the yarn frame lies in the relatively high rigidity of the monofilaments, which makes them prone to breakage and difficult to weave. Therefore, it is necessary to adjust the warp feed tension on the yarn frame to facilitate weaving.

[0070] Please refer to Figure 1 and Figure 4 Embodiment two of the present invention is as follows: A textile process for filling three-dimensional fabrics differs from Embodiment 1 in that, in this embodiment, the first weaving structure 21 is implemented as a multifilament filling area 212.

[0071] For reference Figure 4 The weaving of the multifilament filling area 212 includes: Using multifilament yarns, the yarn is woven in loops on the first and second needle beds in sequence using a yarn frame to form a multifilament filling area 212.

[0072] In this embodiment, the second Jacquard comb uses multifilament yarn, which is woven in loops in the first needle bed and the second needle bed to form a multifilament filling area 212.

[0073] Correspondingly, the weaving of the second weaving structure 22 includes: The second knitting structure 22 is formed by using a jacquard comb to feed the warp through a yarn frame, forming loops on either needle bed in the double needle bed.

[0074] In this embodiment, the second Jacquard comb is woven in loops on the first needle bed to form part of the second braided structure 22 surface layer 1. The tension difference between this structure and the second Jacquard comb in the multifilament filling area 212 is large. The tension is balanced by the yarn frame feeding method, and the partial hollowing out greatly reduces the weight of the fabric.

[0075] Embodiment 3 of the present invention is as follows: A textile process for filling three-dimensional fabrics differs from Embodiment 1 or 2 in that, in this embodiment, based on the weaving method of the monofilament filling area 211 shown in Embodiment 1 and the weaving method of the multifilament filling area 212 shown in Embodiment 2, the monofilament filling area 211 and the multifilament filling area 212 are mixed and woven on a double needle bed to form a composite filling area 213.

[0076] Embodiment four of the present invention is as follows: A textile process for filling three-dimensional fabrics differs from embodiments one to three in that, in this embodiment, the first weaving structure 21 is implemented as a monofilament filling area 211, a multifilament filling area 212, and a composite filling area 213. In other equivalent embodiments, the first weaving structure 21 can also be implemented as a combination of any two of the monofilament filling area 211, the multifilament filling area 212, and the composite filling area 213.

[0077] Meanwhile, in this embodiment, in order to better demonstrate the realization of three-dimensional fabric weaving, machine implementation data of three-dimensional fabric weaving with three first weaving structures 21 are provided as an example.

[0078] Example 1: Machine parameters: warp-knitted jacquard double needle bed three jacquard, machine number E24.

[0079] Raw material specifications: A: 100D polyester DTY; B: 60D / 1F polyester monofilament; C: 150D polyester DTY; D: 100D nylon DTY; Structure, warp threading, and warp delivery: GB2: 1-0-1-1 / 0-1-1-1 / / , full penetration A; JB3.1: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB3.2: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB4.1: 0-1-0-1 / 0-1-2-1 / , 1B1*; JB4.2: 0-1-0-1 / 0-1-2-1 / , 1B1*; JB5.1: 1-1-1-0 / 1-1-0-1 / , 1C1*; Yarn frame JB5.2: 1-1-1-0 / 1-1-0-1 / , 1C1*; Yarn frame GB6: 3-3-4-3 / 0-0-0-1 / / , full penetration D; GB7: 0-0-0-1 / 2-2-2-1 / / , Full D The ground comb GB2 and Jacquard combs JB3.1 and JB3.2 constitute the surface layer, which is a mesh jacquard layer; Jacquard combs BJB4.1 and JB4.2 and Jacquard combs AJB5.1 and JB5.2 constitute the middle layer; ground combs GB6 and GB7 constitute the bottom layer, which is a plain weave layer; the surface layer and the bottom layer are different colors, and there are overlapping monofilament filling areas and yarn frame filling areas; Monofilament filling area: Jacquard combs AJB4.1 and JB4.2 have a weave variation of 0-1-0-1 / 1-1-2-2 / / , which are knitted in loops and weft insertions on needle beds A and B in sequence, with a filling ratio of 100%; Multifilament filling area: Jacquard combs BJB5.1 and JB5.2 have a weave pattern of 2-1-1-0 / 1-2-0-1 / / , which are knitted in circles on needle beds A and B in sequence, with a filling ratio of 100%. Second knitting structure: Jacquard combs B JB5.1 and JB5.2 have a weave variation of 1-2-1-1 / 2-1-1-1 / / , knitted only on the front needle bed, forming part of the second knitting structure surface layer; Jacquard combs AJB4.1 and JB4.2 have a weave variation of 1-1-1-1 / 1-1-3-1 / / , knitted only on the back needle bed, forming part of the second knitting structure bottom layer.

[0080] Example 2: Machine parameters: warp-knitted jacquard double needle bed double jacquard, machine number E28.

[0081] Raw material specifications: A: 75D polyester DTY; B: 100D polyester DTY; C: 60D / 1F polyester monofilament; D: 50D polyester DTY; Structure, warp threading, and warp delivery: GB2: 1-0-1-1 / 0-1-1-1 / / , full penetration A; JB3.1: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB3.2: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB4.1: 1-1-1-0 / 1-1-0-1 / / , 1B1*; yarn frame; JB4.2: 1-1-1-0 / 1-1-0-1 / / , 1B1*; yarn frame; JB5.1: 0-1-0-1 / 0-1-2-1 / / , 1C1*; JB5.2: 0-1-0-1 / 0-1-2-1 / / , 1C1*; GB6: 2-2-1-0 / 1-1-1-2 / 3-3-3-4 / 3-3-3-2 / 3-3-3-4 / 3-3-3-2 / 1-1-1-0 / 1-1-1-2 / / , empty pass D; GB7: 3-3-3-4 / 3-3-3-2 / 1-1-1-0 / 1-1-1-2 / 1-1-1-0 / 1-1-1-2 / 3-3-3-4 / 3-3-3-2 / / , Empty through D.

[0082] The ground comb GB2 and Jacquard combs JB3.1 and JB3.2 constitute the surface layer, which is a mesh jacquard layer; Jacquard combs BJB4.1 and JB4.2, and Jacquard combs AJB5.1 and JB5.2 constitute the intermediate layer; the ground combs GB6 and GB7 constitute the bottom layer, which is a regular mesh layer; there are overlapping monofilament filling areas and multifilament filling areas.

[0083] Monofilament filling area: Jacquard combs AJB5.1 and JB5.2 have a weave variation of 0-1-0-1 / 1-1-2-2 / / and 0-1-0-1 / 1-1-2-2 / / , which are knitted in loops and wefts in sequence on the front and back needle beds, with a filling ratio of 70%.

[0084] Multifilament filling area: Jacquard combs BJB4.1 and JB4.2 have a weave variation of 2-1-1-0 / 1-2-0-1 / / and 1-1-1-1 / 1-1-3-1 / / , which are knitted in circles on the front and back needle beds, with a filling ratio of 70%.

[0085] The second knitting structure: Jacquard combs BJB4.1 and JB4.2 have a weave variation of 1-2-1-1 / 2-1-1-1 / / , knitted only on the front needle bed, forming part of the surface layer of the second knitting structure; Jacquard combs AJB5.1 and JB5.2 have a weave variation of 1-1-1-1 / 1-1-3-1 / / , knitted only in loops on the back needle bed, forming part of the bottom layer of the second knitting structure.

[0086] Example 3: Machine parameters: warp-knitted jacquard double needle bed three jacquard, machine number E24.

[0087] Raw material specifications: A: 100D nylon DTY; B: 100D / 1F nylon monofilament; C: 150D nylon DTY; D: 100D nylon DTY; Structure, warp threading, and warp delivery: GB1: 0-1-1-1 / 2-1-1-1 / / , full penetration A; GB2: 3-2-2-2 / 0-1-1-1 / / , Full penetration A; JB3.1: 0-1-0-1 / 0-1-2-1 / , 1A1*; yarn frame; JB3.2: 0-1-0-1 / 0-1-2-1 / , 1A1*; yarn frame; JB4.1: 0-1-0-1 / 2-3-0-1 / / , 1B1*; yarn frame; JB4.2: 0-1-0-1 / 2-3-0-1 / / , 1B1*; yarn frame; JB5.1: 1-1-1-0 / 0-0-0-1 / / , 1C1*; JB5.2: 1-1-1-0 / 0-0-0-1 / / , 1C1*; GB6: 1-1-1-0 / 1-1-0-1 / / , full penetration D; The ground comb GB6 and Jacquard combs JB5.1 and JB5.2 constitute the top layer, which is a mesh jacquard layer; Jacquard combs BJB4.1 and JB4.2 and Jacquard combs AJB5.1 and JB5.2 constitute the middle layer; and ground combs GB1 and GB2 constitute the bottom layer, which is a plain weave layer.

[0088] Monofilament filling area: Jacquard combs AJB4.1 and JB4.2 have a weave variation of 1-2-0-1 / 2-3-0-1, which are knitted in circles on the front and back needle beds; the filling ratio is 50%.

[0089] Multifilament filling area: Jacquard combs BJB3.1 and JB3.2 have a weave variation of 2-1-1-0 / 1-2-0-1 / / , which are knitted in circles on the front and back needle beds; the filling ratio is 50%.

[0090] The second knitting structure: Jacquard combs BJB3.1 and JB3.2 have a weave variation of 1-1-1-2 / 1-1-2-1 / / , knitted only on the back needle bed, forming part of the surface layer of the second knitting structure; Jacquard combs AJB5.1 and JB5.2 have a weave variation of 0-1-1-1 / 3-4-1-1 / / , knitted only in loops on the front needle bed, forming part of the bottom layer of the second knitting structure.

[0091] Example 4: Machine parameters: warp-knitted jacquard double needle bed three jacquard, machine number E24.

[0092] Raw material specifications: A: 75D polyester DTY; B: 75D polyester + 40D spandex core-spun yarn; C: 60D / 1F polyester monofilament; D: 70D nylon DTY; E: 70D nylon + 40D spandex core-spun yarn; Structure, warp threading, and warp delivery: GB2: 1-0-1-1 / 0-1-1-1 / / , full penetration A; JB3.1: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB3.2: 1-0-1-1 / 1-2-1-1 / / , 1A1*; JB4.1: 1-0-1-1 / 0-1-1-1 / , 1B1*; yarn frame; JB4.2: 1-0-1-1 / 0-1-1-1 / , 1B1*; yarn frame; JB5.1: 0-1-0-1 / 0-1-2-1 / , 1C1*; JB5.2: 0-1-0-1 / 0-1-2-1 / , 1C1*; GB6: 3-3-4-3 / 0-0-0-1 / / , full penetration D; GB7: 0-0-0-1 / 2-2-2-1 / / , full penetration E; The bottom layer consists of the GB2 ground comb and the JB3.1 and JB3.2 jacquard combs, which are mesh jacquard layers; the middle layer consists of the BJB4.1 and JB4.2 jacquard combs and the AJB5.1 and JB5.2 jacquard combs; the top layer consists of the GB6 and GB7 ground combs, which are plain weave layers; the top and bottom layers are different colors.

[0093] Monofilament filling area: Jacquard combs AJB5.1 and JB5.2 have a weave variation of 0-1-0-1 / 1-1-2-2 / / , which are knitted in loops and wefts in sequence on needle bed A and needle bed B, with a filling ratio of 90%.

[0094] Multifilament filling area: Jacquard combs BJB4.1 and JB4.2 have a weave variation of 2-1-2-0 / 1-2-1-2 / / , which are knitted in circles on the front and back needle beds, with a filling ratio of 90%.

[0095] Second knitting structure: Jacquard combs BJB4.1 and JB4.2 have a weave variation of 1-2-1-1 / 2-1-1-1 / / , knitted only in the back, forming part of the surface layer of the second knitting structure; Jacquard combs AJB5.1 and JB5.2 have a weave variation of 1-1-1-1 / 1-1-3-1 / / , knitted only in loops in the front needle bed, forming part of the bottom layer of the second knitting structure.

[0096] Please refer to Figures 5 to 9 Embodiment five of the present invention is as follows: In this embodiment, a three-dimensional filled fabric produced by a textile process for filling three-dimensional fabric implemented in embodiments one to four above will be demonstrated and described.

[0097] For reference Figure 5 A three-dimensional filled fabric, comprising a top layer 1, a middle layer 2, and a bottom layer 3; The top layer 1 and the bottom layer 3 adopt a breathable structure; In this embodiment, the top layer 1 and the bottom layer 3 adopt a plain weave, regular mesh, or jacquard structure, woven with jacquard combs and / or ground combs. There are two jacquard methods: one is jacquard weaving patterns using jacquard combs, and the other is jacquard weaving mesh patterns using both jacquard combs and ground combs. The plain weave / regular mesh is woven with ground combs.

[0098] For reference Figure 6 The intermediate layer 2 includes alternating first braided structures 21 and second braided structures 22. The thickness of the second braided structure 22 is less than the thickness of the first braided structure 21. For reference Figures 7 to 9 The first weaving structure 21 is constructed from at least one of monofilament and multifilament to form a three-dimensional support structure, including at least one of a monofilament filling area 211 woven from monofilament, a multifilament filling area 212 woven from multifilament, and a composite filling area 213 woven from a mixture of monofilament and multifilament.

[0099] In this embodiment, the thickness of the composite filling region 213 and the multifilament filling region 212 is greater than the thickness of the monofilament filling region 211.

[0100] The monofilament filling area 211 is formed by weaving monofilaments in a jacquard manner, and the filling ratio of monofilaments is 20-100%.

[0101] In this embodiment, the weaving of the monofilament filling area 211 is carried out in one of the following two ways: (1) The first Jacquard comb uses monofilament coiled warp feeding, and the loops and wefts are alternately woven in the first needle bed and the second needle bed to form a monofilament filling area 211 with a certain height and thickness, which has good cushioning and support performance. Compared with the reciprocating weaving between the first needle bed and the second needle bed, this structure greatly reduces the yarn tension and the monofilament loops are uniform and flat, and will not be squeezed and deformed.

[0102] Correspondingly, the weaving of the second weaving structure 22 includes: The first jacquard comb is knitted in a long-spanning-needle structure (which can be a heavy warp weft weft structure, a heavy warp loop structure, or a multi-needle plain warp structure with more than 3 needles) on any of the double needle beds. The tension of this structure is close to the knitting tension of the first jacquard comb in the first knitting structure 21, thereby balancing the tension of the coiled head and forming part of the bottom / top layer of the second knitting structure 22, with the center of the second knitting area being hollowed out.

[0103] (2) The first Jacquard comb uses a monofilament yarn frame for warping and performs reciprocating loop knitting on the first and second needle beds to form a monofilament filling area 211, which has a certain height and thickness.

[0104] Correspondingly, the weaving of the second weaving structure 22 includes: The first Jacquard comb is used for loop knitting on either needle bed in the double needle bed. This tension structure is significantly different from the knitting tension of the first Jacquard comb in the first knitting structure 21. The tension is adjusted by the yarn frame feeding method to form part of the bottom / top layer of the second knitting structure 22, and the middle of the second knitting area is hollowed out.

[0105] For reference Figure 7 When using monofilament weaving ( Figure 7 The red threads in the diagram represent monofilament weaving. During the first weaving zone 21, different methods are used to weave the second weaving zone 22 based on different warp feeding methods, forming part of the bottom / top layer of the second weaving zone 22 (e.g., ...). Figure 7 The red section at the bottom of the second weave zone 22 balances the tension. Meanwhile, the middle of the second weave zone 22 features a hollow design, significantly increasing the fabric's breathability and lightness.

[0106] The multifilament filling area 212 is formed by multifilaments woven in a jacquard manner, and the filling ratio of multifilaments is 20-100%.

[0107] In this embodiment, the second Jacquard comb can also be made of multifilament yarn, which is woven in loops in the first needle bed and the second needle bed to form a multifilament filling area 212.

[0108] Correspondingly, the second Jacquard comb is woven in loops on the first needle bed to form part of the second weaving structure 22 surface layer 1; this structure has a large tension difference with the second Jacquard comb in the multifilament filling area 212, and the tension is balanced by the yarn frame feeding method, and the hollow in the middle greatly reduces the weight of the fabric.

[0109] For reference Figure 8 When using monofilament weaving ( Figure 8 The blue threads in the diagram represent multifilament weaving. When weaving the first weaving area 21, the second weaving area 22 is woven using the method described above, forming part of the bottom / top layer of the second weaving area 22 (e.g., Figure 8 The blue section at the top of the second weave zone 22 balances the tension. Meanwhile, the middle of the second weave zone 22 features a hollow design, significantly increasing the fabric's breathability and lightness.

[0110] For reference Figure 9 The composite filling area 213 is formed by mixing and weaving the monofilament filling area 211 and the multifilament filling area 212.

[0111] That is, the second knitting zone 22 adopts single-needle bed directional knitting, that is, the Jacquard comb is only formed in a single loop on the first or second needle bed, and its thickness is much smaller than that of the first knitting zone.

[0112] Specifically, please refer to Figure 7The second weaving area 22, based on the weaving method of the first weaving area 21, selects an appropriate weaving method to form part of the bottom / top layer of the second weaving area 22 (which can be understood as having a certain degree of overlap with the bottom layer 3 / top layer 1), that is... Figure 7 , Figure 8 , Figure 9 In the middle, the top of the openwork area 22 is woven with red / blue fabric, which can balance the tension. Meanwhile, the second weave area 22 in the middle, that is, between the overlapping weave of the surface layer 1 and the bottom layer 3, adopts an openwork design, which significantly increases the lightness and breathability of the fabric.

[0113] In summary, this invention provides a textile process and a three-dimensional filled fabric. The process involves layering the top, bottom, and middle layers using a comb and bar. The first weaving structure employs a double-needle bed weaving method, where monofilaments and / or multifilaments form a three-dimensional support, ensuring a three-dimensional effect without increasing fiber density and solving the problem of heaviness. The second weaving structure uses one needle bed from the double needle bed to reduce yarn usage and create breathable gaps, improving breathability. In the monofilament filling area, tension is controlled by warp feeding via a yarn bed or crease, combined with loop formation and weft insertion to prevent monofilaments from being squeezed out due to uneven stress. In the multifilament filling area, loops are formed sequentially using a crease, enhancing softness and fluffiness, and working synergistically with the monofilaments to optimize the hand feel. Diverse weaving methods (such as long-cross stitches and reciprocating loop formation) enhance process flexibility, adapting to different support and softness requirements. The final product enhances the three-dimensional effect through the thickness difference between the filling and the second weaving structure, combining lightweight, high breathability, structural stability, and a delicate hand feel, suitable for various applications such as clothing and home furnishings.

[0114] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for weaving a filled three-dimensional fabric, characterized in that, This includes the weaving steps for creating an intermediate layer between the fabric surface and the base layer: The yarns of the intermediate layer are controlled to be knitted alternately between the double needle beds to form the first knitting structure of the three-dimensional support structure; The yarn of the intermediate layer is controlled to be knitted independently on one of the needle beds of the double needle bed to form a second knitting structure; The first and second weave structures are alternately woven.

2. The weaving method for a filled three-dimensional fabric according to claim 1, characterized in that, The first weaving structure is woven from monofilaments and / or multifilaments.

3. The weaving method for a filled three-dimensional fabric according to claim 2, characterized in that, The monofilaments are fed using a coiled head.

4. The weaving method for a filled three-dimensional fabric according to claim 3, characterized in that, include: The monofilament is woven between two needle beds using a Jacquard comb in a looping and weft-insertion manner.

5. The weaving method for a filled three-dimensional fabric according to claim 4, characterized in that, The weaving of the second weaving structure includes: Long-cross stitch weaving is performed on one of the needle beds of the double needle bed using a Jacquard comb.

6. A method for weaving a filled three-dimensional fabric according to claim 5, characterized in that, The long-spanning needle structure is at least one of the following: heavy warp weft weft structure, heavy warp loop structure, or multi-needle warp plain structure with 3 or more needles.

7. The weaving method for a filled three-dimensional fabric according to claim 2, characterized in that, The monofilaments are fed using a yarn frame.

8. A method for weaving a filled three-dimensional fabric according to claim 7, characterized in that, include: The monofilament is woven in loops between two needle beds by Jacquard combs.

9. A method for weaving a filled three-dimensional fabric according to claim 8, characterized in that, The weaving of the second weaving structure includes: Loop knitting is performed using a Jacquard comb on either of the two needle beds.

10. A method for weaving a filled three-dimensional fabric according to claim 2, characterized in that, The multifilament yarn is fed by a yarn frame.

11. A method for weaving a filled three-dimensional fabric according to claim 10, characterized in that, include: The multifilaments are woven in loops between two needle beds by Jacquard combs.

12. A method for weaving a filled three-dimensional fabric according to claim 11, characterized in that, The weaving of the second weaving structure includes: Loop knitting is performed using a Jacquard comb on either of the two needle beds.

13. The method for weaving a filled three-dimensional fabric according to claim 1, characterized in that, It also includes the weaving steps for the bottom and top layers: It is woven from at least one of jacquard combs and ground combs, in a plain weave, regular mesh, or jacquard pattern.

14. A method for weaving a filled three-dimensional fabric according to claim 13, characterized in that, The bottom layer and the top layer are woven with different weaving methods; One layer is woven in a plain weave, while the other layer is woven in a regular mesh or jacquard pattern.

15. A three-dimensional filled fabric, woven by the weaving method of any one of claims 1-14.

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