Weaving method of warp-knitted three-dimensional fabric based on different front and back needle densities and fabric

Abstract

The invention discloses a weaving method of a warp-knitted three-dimensional fabric based on different front and back needle densities and the fabric. The weaving method comprises the following steps: a full threading step: forming a base surface layer by a front needle bed in a full threading manner; an interval threading step: a rear needle bed performs threading in a one-to-one threading manner to form an observation surface layer, the observation surface layer and the base surface layer are connected through connecting yarns, the observation surface layer comprises a mesh part, a non-mesh part and a jacquard weave, and the jacquard weave is one or two of a thin yarn weave and a mesh weave; wherein the needle density of the base surface layer is twice that of the observation surface layer. The fabric is obtained through the weaving method.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of textile production, in particular to a weaving method of warp-knitted three-dimensional fabric with different needle densities in front and back and a fabric. BACKGROUND

[0002] Warp-knitted three-dimensional fabric, especially sandwich mesh fabric, is widely used in shoe materials, clothing, sports medical supplies and other fields due to its advantages of loftiness, air permeability, lightness and the like. The traditional warp-knitted three-dimensional fabric is usually woven on a double-needle bed warp knitting machine, and the needle pitch (i.e. needle density) of the front and back two needle beds is the same. For example, the fabric woven on a 24E (24 needles per inch) machine has a needle density of 24E on both the front and back sides, and the size and density of the mesh formed are basically consistent. Although this symmetrical structure meets the basic performance requirements, it has limitations in appearance style and functional diversity. With the increasing demand for product individualization and functional differentiation in the market, consumers and brand owners hope that the fabric can present more diverse visual effects and tactile experiences. For example, in shoe upper materials, one side needs delicate and close touch to improve comfort, and the other side needs rough and full mesh to enhance air permeability and unique appearance; in packaging or decorative materials, the front and back sides form different styles, which can also bring stronger design sense.

[0003] At present, the warp-knitted three-dimensional fabric on the market is difficult to realize significant differences in needle density and style contrast between the front and back sides on the same product. If you want to get different effects on both sides, you usually need to compound two different specifications of fabric after production, which not only increases the complexity and cost of production process, but also may affect the softness, air permeability and environmental protection of the fabric due to the use of adhesive. In addition, the existing warp-knitted three-dimensional fabric is also relatively simple in mesh structure design, and it is difficult to realize the staggered distribution of mesh parts and non-mesh parts, as well as the flexible combination of semi-transparent and transparent organizations, which limits its application potential in special visual effects and functionality. SUMMARY

[0004] The present application aims to at least solve one of the problems in the prior art. To this end, the present application proposes a weaving method of warp-knitted three-dimensional fabric with different needle densities in front and back and a fabric, which has the advantages of realizing significant differences in needle density and style contrast between the front and back sides on the same product, obtaining different effects on both sides without the need for post-compounding, reducing cost, and improving air permeability and design sense.

[0005] In a first aspect, the weaving method of warp-knitted three-dimensional fabric with different needle densities in front and back according to the embodiments of the present application comprises the following steps: Full-threading step: the front needle bed adopts a full-threading yarn method to form a base surface layer, The interval threading step: the back needle bed adopts the way of threading one empty one to form the observation surface layer, the observation surface layer is connected with the base surface layer through connecting yarn, and the observation surface layer comprises mesh parts, non-mesh parts and jacquard structures, and the jacquard structures are one or both of yarn thin structures and mesh structures. Among them, the needle density of the base surface layer is twice the needle density of the observation surface layer.

[0006] The weaving method of the warp-knitted three-dimensional fabric based on different needle densities of front and back according to the embodiment of the application has at least the following beneficial effects: the front needle bed is fully threaded to form a high-density base surface layer to provide a fabric basic support structure; the back needle bed is interval threaded to form a low-density observation surface layer, and the yarn arrangement of one empty one is used to form a designable mesh area. The base surface layer and the observation surface layer form a three-dimensional interval structure through connecting yarn, and the combination of yarn thin and mesh of the jacquard structure is used to form a visual effect of transparent and semi-transparent areas alternately in the observation surface layer. By setting the needle density of the base surface layer to be twice the needle density of the observation surface layer, the high-strength support of the base surface layer is ensured, and the mesh aperture of the observation surface layer is increased, realizing the structure characteristics of the difference between the front and back needle densities. In the full threading step, the front needle bed is fully threaded to form a dense base, providing tension balance for the mesh area formed by the interval threading of the back needle bed; in the interval threading step, the back needle bed is selectively absent to form mesh and non-mesh alternately distributed, and the combination of yarn thin and mesh of the jacquard structure is used to realize the free arrangement of transparent and semi-transparent areas on a single fabric.

[0007] The weaving method of the warp-knitted three-dimensional fabric based on different needle densities of front and back according to the embodiment of the application, the needle density of the double needle bed warp knitting machine is 24 needles, in the full threading step, the base surface layer forms a needle density of 24 needles, and in the interval threading step, the observation surface layer forms a needle density of 12 needles.

[0008] The weaving method of the warp-knitted three-dimensional fabric based on different needle densities of front and back according to the embodiment of the application, in the interval threading step, the back jacquard guide bar JB6-1 adopts the yarn laying code 0-0-0-0 / 3-3-3-3 / / to form a yarn thin structure, and the back jacquard guide bar JB6-2 adopts the yarn laying code 0-0-0-0 / 2-2-2-2 / / to form a mesh structure.

[0009] The weaving method of the warp-knitted three-dimensional fabric based on different needle densities of front and back according to the embodiment of the application, the jacquard structure is any one of the following combinations: A, the jacquard structure is a yarn thin structure + a mesh structure; B, the jacquard structure is a mesh structure + a yarn thin structure; C, the jacquard structure is a yarn thin structure + a yarn thin structure; D, the jacquard structure is a mesh structure + a mesh structure.

[0010] In the full-threading step, the ground bar guide bar GB1 of the front needle bed adopts a warp pile stitch with a filling number code of 1-0-1-1 / 2-3-3-3 / / , and the ground bar guide bar GB2 of the front needle bed adopts a warp plain stitch with a filling number code of 1-2-1-1 / 1-0-1-1 / / .

[0011] In the interval-threading step, the ground bar guide bars GB5 and GB7 of the back needle bed form the mesh portion of the observation surface layer, the filling number code of the GB5 is (2-2-1-0 / 0-0-2-3)*2 / (3-3-4-5 / 3-3-3-2)*2 / / 1-threading 3-empty-threading, and the filling number code of the GB7 is (3-3-4-5 / 3-3-3-2)*2 / (2-2-1-0 / 0-0-2-3)*2 / / empty-threading 3-threading.

[0012] In a second aspect, a fabric according to an embodiment of the present application is obtained by the above-mentioned weaving method of the warp-knitted three-dimensional fabric with different needle densities in front and back, and includes: a base surface layer; an observation surface layer arranged above the base surface layer, the observation surface layer being connected with the base surface layer through connecting yarns, the observation surface layer including mesh portions, non-mesh portions, and Jacquard stitches, the mesh portions and the non-mesh portions being arranged alternately along a first direction, and the mesh portions and the non-mesh portions being arranged alternately along a second direction, the first direction being perpendicular to the second direction, the Jacquard stitches being filled in the mesh portions and the non-mesh portions, the Jacquard stitches being arranged along the second direction, and the Jacquard stitches being one or both of a yarn-thin stitch and a mesh stitch; wherein the needle density of the base surface layer is twice the needle density of the observation surface layer.

[0013] The fabric according to the embodiment of the present application has at least the following beneficial effects: the present application realizes the difference in needle density of the front and back surfaces through the double-layer structure design of the base surface layer and the observation surface layer. The base surface layer serves as a basic support layer, and the observation surface layer forms a three-dimensional level through the staggered arrangement of the mesh portion and the non-mesh portion in the warp and weft directions, and is combined with the filling of the jacquard organization arranged along the second direction, so that the structural stability is maintained and visual contrast is formed. Through the differential needle density design of the base surface layer and the observation surface layer and the staggered arrangement of the mesh portion and the non-mesh portion, combined with the flexible combination of the semi-transparent and transparent organizations, the problem of single style of the front and back surfaces of the traditional fabric and the need for post-combination is solved, and the fabric has the advantages of simple structure, one-piece forming, and simultaneous realization of the significant needle density difference and style contrast of the front and back surfaces. The connecting yarn combines the two layers into a whole, avoiding the use of adhesive in the traditional combination process. The staggered arrangement of the mesh portion and the non-mesh portion enhances the air permeability and the touch difference, and the jacquard organization adopts transparent or semi-transparent material to further enrich the optical effect. The needle density difference of the base surface layer and the observation surface layer directly forms the different density characteristics of the two surfaces, and the differential requirements of function and appearance can be realized without post-combination.

[0014] The yarn of the ground combing guide of the front needle bed is polyester DTY yarn according to the embodiment of the present application.

[0015] The yarn of the back jacquard combing guide is cationic DTY yarn or polyester DTY yarn according to the embodiment of the present application.

[0016] The yarn of the ground combing guides GB5 and GB7 of the back needle bed is polyester DTY yarn or cationic DTY yarn according to the embodiment of the present application.

[0017] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0018] The above and / or additional aspects and advantages of the present application will become apparent and be readily understood from the following description, taken in conjunction with the accompanying drawings, in which: Figure 1 A structure cross-sectional view of a first embodiment of a warp-knitted three-dimensional fabric with different needle densities of the front and back surfaces according to the embodiment of the present application; Figure 2 A front view structure schematic diagram of a first embodiment of a warp-knitted three-dimensional fabric with different needle densities of the front and back surfaces according to the embodiment of the present application; Figure 3 A structure cross-sectional view of a second embodiment of a warp-knitted three-dimensional fabric with different needle densities of the front and back surfaces according to the embodiment of the present application; Figure 4 A front view structure schematic diagram of a second embodiment of a warp-knitted three-dimensional fabric with different needle densities of the front and back surfaces according to the embodiment of the present application; Figure 5 FIG. 3 is a schematic view of a cross-sectional structure of a third embodiment of a warp-knitted three-dimensional fabric according to the present application, which has different needle counts in front and back; Figure 6 FIG. 4 is a schematic view of a front structure of a third embodiment of a warp-knitted three-dimensional fabric according to the present application, which has different needle counts in front and back; Figure 7 FIG. 5 is a schematic view of a cross-sectional structure of a fourth embodiment of a warp-knitted three-dimensional fabric according to the present application, which has different needle counts in front and back; Figure 8 FIG. 6 is a schematic view of a front structure of a fourth embodiment of a warp-knitted three-dimensional fabric according to the present application, which has different needle counts in front and back; Figure 9 FIG. 7 is a schematic view of a base surface layer according to the present application, which is about a number of ground combing on a front needle bed of a warp knitting machine; Figure 10 FIG. 8 is a schematic view of an observation surface layer according to the present application, which is about a number of ground combing on a back needle bed of a warp knitting machine when a jacquard stitch is not filled; Figure 11 FIG. 9 is a schematic view of an observation surface layer according to the present application, which is filled with a jacquard stitch (transparent stitch + semi-transparent stitch); Figure 12 FIG. 10 is a schematic view of an observation surface layer according to the present application, which is filled with a jacquard stitch (semi-transparent stitch + transparent stitch); Figure 13 FIG. 11 is a schematic view of an observation surface layer according to the present application, which is filled with a jacquard stitch (transparent stitch + transparent stitch); BRIEF DESCRIPTION OF DRAWINGS Base surface layer 100 Observation surface layer 200; Mesh portion 210; Non-mesh portion 220; Semi-transparent stitch 230; Transparent stitch 240 Connecting yarn 300 DETAILED DESCRIPTION

[0019] Embodiments of the present application are described in detail below with reference to the attached drawings, which show by way of example, embodiments in which like numerals indicate like elements or elements having the same or similar function throughout the several views. The embodiments described below are merely exemplary for the purpose of explanation and are not to be understood as limiting the present application.

[0020] In the description of the present application, it should be understood that, in relation to the orientation description, for example, the orientation or position relationship indicated by the upper, lower, front, back, left, right, etc. is based on the orientation or position relationship shown in the drawings, which is only for the purpose of facilitating the description of the present application and simplifying the description, and therefore cannot be understood as a limitation on the present application.

[0021] In the description of the invention, the meaning of one or more is one or more, the meaning of multiple is two or more, greater than, less than, more than, etc. are understood as not including the number, above, below, within, etc. are understood as including the number. If the first, second is described, it is only for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features or implicitly indicating the sequence of indicated technical features.

[0022] In the description of the invention, unless otherwise explicitly limited, the words such as setting, installing, connecting, etc. should be broadly understood, and those skilled in the art can reasonably determine the specific meaning of the above words in the invention in combination with the specific content of the technical solution.

[0023] In the prior art, warp-knitted three-dimensional fabric is usually woven by using a double needle bed warp knitting machine, and the same needle density is configured on the front needle bed and the back needle bed. This symmetrical structure leads to the fact that the mesh density and style of the front and back surfaces of the fabric are completely consistent, which is difficult to meet the market demand for differentiated visual effects and functionality. For example, in shoe material applications, when one side of the fabric needs to have a delicate touch and the other side needs to have a rough mesh structure, the traditional process needs to realize this by compounding different fabrics after the production, which increases the production cost and affects the air permeability of the material. In order to solve the above problems, the researchers found that the core of restricting the style differentiation of the fabric lies in the symmetry of the needle density configuration. By analyzing the yarn arrangement principle of the double needle bed warp knitting machine, the full needle yarn of the front needle bed is combined with the interval yarn of the back needle bed, and the combination application of the jacquard organization in the single layer fabric is explored. After many test verifications, it is found that the full needle yarn of the front needle bed forms a high-density base layer, the selective missing yarn of the back needle bed forms a low-density observation layer, and the three-dimensional knitting of the connecting yarn 300 can realize the synchronous construction of different needle densities on the single layer fabric.

[0024] Therefore, the present application proposes a weaving method of warp-knitted three-dimensional fabric based on different needle densities of the front and back, which is realized by using a double needle bed warp knitting machine, and includes the following steps: In the full needle step, the front needle bed uses a full needle yarn method to form a base surface layer 100; In the interval yarn step, the back needle bed uses a one-in-one-out method to form an observation surface layer 200, and the observation surface layer 200 and the base surface layer 100 are connected by a connecting yarn 300. The observation surface layer 200 includes a mesh part 210, a non-mesh part 220, and a jacquard organization, and the jacquard organization is one or both of a yarn-thin organization and a mesh organization; wherein the needle density of the base surface layer 100 is twice the needle density of the observation surface layer 200.

[0025] The full-threading yarn mode refers to that all the needles of the front needle bed are threaded with yarns, and the continuous yarn feeding mode of the ground combing bar can be specifically used to realize the full-threading yarn mode, and the full-threading yarn mode forms a dense fabric layer without gaps. The interval threading yarn mode refers to that every other needle of the back needle bed is threaded with yarns, and the skip threading process can be specifically used to realize the interval threading yarn mode, and the interval threading yarn mode forms a mesh structure by selective yarn absence. The needle density ratio of the base surface layer 100 to the observation surface layer 200 is realized by adjusting the threading density of the front and back needle beds, for example, the full-threading yarn mode of the front needle bed forms a 24-needle density, and the back needle bed forms a 12-needle density by threading one and leaving one. The jacquard weave includes yarn-thin weave and mesh weave, and the yarn-thin weave and the mesh weave can be specifically realized by the control of the lapping motion of the jacquard combing bar. The yarn-thin weave forms a semi-transparent area by local absence of lapping, and the mesh weave forms a fully transparent area by yarn crossing.

[0026] Specifically, the full-threading yarn of the front needle bed forms a high-density base layer to provide basic support for the fabric. In the low-density observation layer formed by the interval threading yarn of the back needle bed, the absence of yarns naturally forms a mesh structure, and the threading position forms a non-mesh solid area. The connecting yarn 300 performs looping motion between the front and back needle beds to connect the two layers of fabric into a three-dimensional structure. The jacquard weave alternately forms yarn-thin areas and mesh areas on the observation layer by controlling the yarn path, wherein the yarn-thin areas achieve a semi-transparent effect by reducing yarn coverage, and the mesh areas form fully transparent holes by yarn crossing. The base layer has a needle density twice that of the observation layer, so that the yarn density of the base layer is twice that of the observation layer, which not only ensures the structural strength of the base layer, but also expands the mesh aperture of the observation layer by twice.

[0027] Compared with the prior art, the traditional method needs to realize the difference between the two sides by compounding two different needle density fabrics, while the present scheme directly forms different needle density layers by single weaving. The mesh structure in the prior art is limited by uniform needle density and cannot realize staggered distribution, while the present scheme forms a pattern of alternating mesh and non-mesh by the synergistic effect of interval threading yarn and jacquard weave in a single layer of fabric. In the traditional process, the connecting yarn is only used for interlayer fixation, while in the present scheme, the connecting yarn participates in the formation of the mesh structure of the observation layer.

[0028] Through the above technical scheme, the present application realizes the differentiated configuration of the needle density of the base surface layer 100 and the observation surface layer 200 on a single layer of fabric, so that the front and back of the fabric respectively present the contrast effect of dense and smooth and rough mesh. The staggered distribution of mesh and non-mesh areas in the observation surface layer 200, combined with the combined application of yarn-thin and mesh weave, forms a transparent visual effect with a sense of hierarchy. The high-needle-density structure of the base surface layer 100 provides stable support for the fabric, and the low-needle-density configuration of the observation surface layer 200 significantly improves the mesh air permeability. The connecting yarn 300 fixes the double-layer fabric while participating in the construction of the three-dimensional mesh structure of the observation layer, avoiding the influence of adhesives on the material performance in the traditional compounding process.

[0029] The application further proposes that in the interval threading step, the back jacquard bar JB6-1 adopts the threading code 0-0-0-0 / 3-3-3-3 / / to form the yarn thin organization, and the back jacquard bar JB6-2 adopts the threading code 0-0-0-0 / 2-2-2-2 / / to form the mesh organization.

[0030] Specifically, the threading code 0-0-0-0 / 3-3-3-3 / / of the back jacquard bar JB6-1 keeps the yarn in place in the continuous four knitting strokes, and then performs a 3-gauge lateral shift in the next cycle. This movement mode makes the yarn form a longitudinally extended sparse coverage on the fabric surface, producing a translucent yarn thin effect. At the same time, the threading code 0-0-0-0 / 2-2-2-2 / / of the back jacquard bar JB6-2 performs a 2-gauge lateral shift in the same knitting cycle, resulting in an expansion of the spacing between adjacent yarns, forming regularly distributed mesh holes. The difference in the threading codes of the two groups of bars ensures that the yarn thin organization and the mesh organization form a clear boundary in spatial distribution, avoiding the blurring of the organizational structure caused by the overlapping of yarns.

[0031] The application further proposes that in the full threading step, the ground bar GB1 of the front needle bed adopts the warp pile organization with the threading code 1-0-1-1 / 2-3-3-3 / / , and the ground bar GB2 of the front needle bed adopts the warp plain organization with the threading code 1-2-1-1 / 1-0-1-1 / / .

[0032] Specifically, the ground bar GB1 forms the basic support structure of the base surface layer through the diagonal extension line of the warp pile organization, and the ground bar GB2 further fills the loop gap through the alternative coverage mode of the warp plain organization. The two groups of bars work together to make the base surface layer 100 maintain high needle density while being flexible. That is, the warp pile organization of the ground bar GB1 forms a longitudinally staggered loop structure through the diagonally offset threading path, increasing the number of interlacing points of the yarn of the base surface layer 100 in the longitudinal direction, and the warp plain organization of the ground bar GB2 forms a horizontally continuous loop structure through the symmetric lateral movement path, balancing the extension force of the yarn in the horizontal direction. The threading codes of the two groups of bars form complementary knitting tracks when the loops are formed alternately on the front and back needle beds, so that the yarn produces uniformly distributed mechanical support points in the longitudinal and horizontal directions, avoiding the distortion of the fabric caused by the single extension direction of the yarn during single-bar knitting. Through the synergistic effect of the two groups of bars, the base surface layer 100 can realize accurate control of the needle density under the full threading condition, for example, forming a needle density of 24 needles on a needle bed of 24 needles, providing a stable structural basis for the interval threading of the observation surface layer 200.

[0033] The application further proposes that in the interval threading step, the ground comb bars GB5 and GB7 of the back needle bed form the mesh part 210 of the observation surface layer 200, the threading number code of GB5 is (2-2-1-0 / 0-0-2-3)*2 / (3-3-4-5 / 3-3-3-2)*2 / / thread 1, leave 3, and the threading number code of GB7 is (3-3-4-5 / 3-3-3-2)*2 / (2-2-1-0 / 0-0-2-3)*2 / / leave 3, thread 1.

[0034] Wherein, thread 1, leave 3 means that one yarn is threaded every three needle positions, which can be realized by threading a yarn every three guide holes on the comb bar, and this threading method can form sparse yarn distribution. Leave 3, thread 1 means that one guide hole is left empty every three needle positions, which can be realized by reserving one position without threading a yarn every three guide holes on the comb bar, and this threading method forms a complementary structure with thread 1, leave 3. The threading number code (2-2-1-0 / 0-0-2-3)*2 / (3-3-4-5 / 3-3-3-2)*2 / / represents the horizontal movement trajectory of the comb bar GB5, and by alternately moving the back of the needle by a short distance and a long distance, the opening form of the mesh structure is formed. The threading number code (3-3-4-5 / 3-3-3-2)*2 / (2-2-1-0 / 0-0-2-3)*2 / / represents the horizontal movement trajectory of the comb bar GB7, and the direction of the back of the needle is symmetrically complementary to GB5, thereby forming stable mesh pores on the surface of the fabric.

[0035] Specifically, the comb bar GB5 adopts the threading method of thread 1, leave 3 to cooperate with the specific threading number code, so that the yarn forms an interval distribution loop structure in the longitudinal direction. The comb bar GB7 adopts the threading method of leave 3, thread 1, and the direction of the back of the needle in the threading number code is mirror-symmetric to GB5, and the yarns of the two comb bars are staggered when interlaced. Through the coordinated movement of GB5 and GB7, the yarns alternately form open areas and closed areas in the horizontal and vertical directions, and finally build a uniform distribution of diamond mesh structure on the observation surface layer 200. The size of the pores of the mesh part 210 can be controlled by adjusting the amount of horizontal movement in the threading number code, for example, setting the back of the needle to move 2-3 needle pitches can form a medium-sized mesh.

[0036] Compared with the prior art, the traditional warp-knitted fabric mesh structure usually adopts a uniform threading method of a single comb bar, resulting in fixed mesh distribution density and unable to form staggered pores. The present scheme adopts the complementary threading methods of thread 1, leave 3 and leave 3, thread 1 by two groups of comb bars, and cooperates with the symmetric threading movement trajectory, so that the mesh structure is staggered in the warp and weft directions. This design breaks through the technical limitation of single pore direction of traditional mesh fabric, and realizes the construction of multi-dimensional ventilation channels.

[0037] Beneficially, the present application can form a mesh structure with staggered apertures on the observation surface layer 200, effectively improving the air permeability of the fabric. The staggered distribution of the mesh portion 210 avoids the local strength reduction caused by the concentration of apertures, while enhancing the visual level of the fabric. The complementary threading method combined with the lapping motion allows the mesh shape to be flexibly adjusted as needed, providing more diversified structural design possibilities for warp-knitted three-dimensional fabrics.

[0038] Referring Figures 1 to 13 , the present application provides a fabric obtained by the above weaving method, comprising a warp-knitted three-dimensional fabric including a base surface layer 100 and an observation surface layer 200. The observation surface layer 200 is arranged above the base surface layer 100 and is combined by connecting yarns 300. The observation surface layer 200 includes mesh portions 210 and non-mesh portions 220 arranged staggered along a first direction, mesh portions 210 arranged staggered along a second direction, and a jacquard weave arranged along the second direction. The jacquard weave is composed of a semi-transparent weave 230 or a transparent weave 240, filling the surface of the mesh portions 210 and the non-mesh portions 220.

[0039] Among them, the base surface layer 100 refers to the fabric bottom layer as a supporting structure, which can be formed by interweaving warp pile weave and warp flat weave to provide mechanical support through tight knitting. The observation surface layer 200 refers to the surface layer with decorative function, which forms a low-density structure through the threading method of one empty one, providing space for the staggered arrangement of meshes. The mesh portion 210 refers to the transparent area formed by the incomplete coverage of yarns, which can be achieved by interval knitting, used to enhance air permeability and form visual contrast. The non-mesh portion 220 refers to the solid area covered by yarns, used to provide a tactile support surface. The jacquard weave refers to the decorative structure formed by jacquard technology, which is woven with semi-transparent or transparent yarns, capable of forming a gradual optical effect in the mesh area.

[0040] Specifically, the base surface layer 100 uses full-thread yarns to form a high-density knitting structure, ensuring the overall strength of the fabric. The observation surface layer 200 forms a low-density base through interval threading, and the transparent mesh and solid area are arranged staggered in both warp and weft directions. The connecting yarns 300 penetrate the two-layer structure in the vertical direction, forming a stable three-dimensional shape. The jacquard weave is arranged along the lateral direction of the fabric, using transparent yarns in the mesh area to form a perspective effect, and using semi-transparent yarns in the non-mesh area to form a matte texture. When a specific visual effect is needed, transparent and semi-transparent yarns can be used in combination to form a gradual light and shade in the staggered area.

[0041] It can be understood that the semi-transparent weave 230 and the transparent weave 240 can have the following combinations: As Figure 3 , 4When the jacquard organization is (semi-transparent organization 230) + (transparent organization 240), as shown in FIG. 12, the two form a dark filling effect in the mesh of the observation surface layer 200. This is because the floating line covering part of the semi-transparent organization 230 blocks part of the light, while the mesh part 210 of the transparent organization 240 allows the light to fully penetrate, and the contrast between the two forms the visual effect of dark filling.

[0042] As shown in FIG. 11, when the jacquard organization is (transparent organization 240) + (semi-transparent organization 230), the two form a light filling effect in the mesh of the observation surface layer 200. This is because the mesh part 210 of the transparent organization 240 allows the light to fully penetrate, while the floating line covering part of the semi-transparent organization 230 scatters the light, making the overall visual effect brighter, forming a light filling. Figure 1 2 As shown in FIG. 11, when the jacquard organization is (transparent organization 240) + (semi-transparent organization 230), the two form a light filling effect in the mesh of the observation surface layer 200. This is because the mesh part 210 of the transparent organization 240 allows the light to fully penetrate, while the floating line covering part of the semi-transparent organization 230 scatters the light, making the overall visual effect brighter, forming a light filling.

[0043] As shown in FIG. 12, when the jacquard organization is (semi-transparent organization 230) + (semi-transparent organization 230), the two form a light and dark effect in the mesh of the observation surface layer 200. This is because different semi-transparent organization 230 regions may differ in floating line coverage area, resulting in different degrees of light scattering and forming a visual effect of varying lightness. Figure 5 6 As shown in FIG. 13, when the jacquard organization is (transparent organization 240) + (transparent organization 240), the two form a transparent effect in the mesh of the observation surface layer 200. This is because the mesh part 210 of the transparent organization 240 allows the light to fully penetrate without obstruction, forming a clear transparent visual effect.

[0044] As shown in FIG. 13, when the jacquard organization is (transparent organization 240) + (transparent organization 240), the two form a transparent effect in the mesh of the observation surface layer 200. This is because the mesh part 210 of the transparent organization 240 allows the light to fully penetrate without obstruction, forming a clear transparent visual effect. Figure 7 8 As shown in FIG. 13, when the jacquard organization is (transparent organization 240) + (transparent organization 240), the two form a transparent effect in the mesh of the observation surface layer 200. This is because the mesh part 210 of the transparent organization 240 allows the light to fully penetrate without obstruction, forming a clear transparent visual effect.

[0045] Beneficially, the difference in needle density between the base surface layer 100 and the observation surface layer 200 directly forms the double-sided different density characteristics, without the need for a complex process to achieve touch grading. The mesh and non-mesh areas are staggered in the warp and weft directions, allowing the single-layer fabric to have both breathable and solid areas. The continuous arrangement of the jacquard organization in the horizontal direction makes the transparent and semi-transparent effects regularly present along the width direction of the fabric, forming dynamic visual levels. The three-dimensional penetration of the connecting yarn 300 maintains the stability of the structure while maintaining the overall lightness of the fabric.

[0046] Specifically, the base surface layer 100 includes a warp pile weave and a warp flat weave.

[0047] ​​​It should be noted that the warp-pile weave refers to the formation of a highly covering fabric surface through an extended loop structure. Specifically, this can be achieved by using a front needle bed comb to fully thread yarns and form continuous extended stitches. This structure provides basic support and dimensional stability to the base layer 100. The warp plain weave refers to the cross-weaving between adjacent warp rows to form a tight connection. Specifically, this can be achieved by using a front needle bed comb to fully thread yarns and alternately looping adjacent warp rows. This structure enhances the longitudinal strength and deformation resistance of the base layer 100.

[0048] Understandably, the alternating weave of the ply and plain warp structures forms a composite structure. The extended stitches of the ply cover the surface of the base layer 100, forming a continuous support surface, while the cross-weave of the plain warp creates a locking structure in the longitudinal direction. The interweaving of these two structures achieves a balance between the transverse extensibility and longitudinal tensile strength of the base layer 100. During the weaving process, the extended stitches of the ply are configured to cover the main areas of the base layer 100, while the cross-weave of the plain warp is configured to be spaced apart between the ply stitches, resulting in complementary mechanical properties through the alternating arrangement of the two structures.

[0049] Compared to existing technologies, the base layer 100 of traditional warp-knitted three-dimensional fabrics uses only a single weave structure, such as warp plain weave or warp pile weave, resulting in performance shortcomings in transverse stretchability, longitudinal strength, or surface coverage. This solution, through a composite structure design, allows the base layer 100 to possess both the soft stretchability of a warp pile weave and the structural compactness of a warp plain weave. This overcomes the limitation of a single weave structure in simultaneously meeting multi-dimensional mechanical requirements, achieving synergistic optimization between support strength and flexibility. This enables the base layer 100 to meet the dual demands of a delicate feel and deformation resistance in footwear materials, or to simultaneously satisfy the requirements of surface smoothness and longitudinal tear resistance in packaging materials.

[0050] Furthermore, the base layer 100 is formed by the front needle bed comb fully threading the yarn.

[0051] Specifically, when the front needle bed comb is fully threaded, the yarn is evenly distributed across all needle positions during the formation of the base layer 100. This full-thread method creates an uninterrupted warp or plywood weave structure in the base layer 100, eliminating yarn gaps compared to a non-full-thread method. During knitting, the fully threaded yarn forms a dense base layer through continuous looping, and its high-density structure provides stable anchoring points for subsequent connecting yarns 300. Simultaneously, the high needle density of the base layer 100 complements the low needle density of the observation layer 200, preventing overall fabric structural imbalance due to differences in needle density between the two sides.

[0052] Beneficially, this solution achieves a high-density structure on the base layer 100 by fully threading the yarn through the front needle bed comb, eliminating the need for subsequent composite processes to achieve differences in needle density on both sides. This single-sided full-threading method maintains the fabric's integrity while eliminating the loss of breathability caused by adhesives, and solves the structural symmetry limitations resulting from identical needle density on both sides in traditional processes. The high-density structure of the base layer 100 provides a supporting foundation for the low-density mesh of the observation layer 200, enabling the fabric to form a stable double-sided differential density structure in a single knitting process. The continuous knitting layer formed by the full-threading yarn effectively prevents displacement of the connecting yarns 300, ensuring the dimensional stability of the three-dimensional fabric under differences in needle density on both sides.

[0053] According to some embodiments of this application, the observation layer 200 is formed by threading yarn through a back needle bed comb and a back Jacquard comb in a one-through-one-out manner.

[0054] It should be noted that the "one-through-one-out" method refers to the guide needles of the comb threading the yarn through every other needle position. Specifically, an odd or even number of guide needles can be used to thread the yarn while the remaining guide needles are left empty. This reduces the number of yarns per unit length, thereby lowering the density of the observed surface layer by 200 needles.

[0055] That is, the back needle bed comb and the back Jacquard comb use an intermittent yarn threading method when threading yarn, which reduces the number of yarns actually involved in weaving per inch. For example, when the base layer 100 is fully threaded with yarn using the front needle bed comb to form a 24-stitch density, the observation layer 200 only forms a 12-stitch density by threading one stitch and leaving one stitch empty. During the weaving process, the back Jacquard comb controls the yarn direction according to the preset pattern, and performs weft insertion or loop forming operations in the alternating areas of the mesh area 210 and the non-mesh area 220, thereby forming a combination structure of semi-transparent structure 230 and transparent structure 240 within the same observation layer 200. This weaving method allows the observation layer 200 to directly form sparse stitch density and differentiated textures in a single weaving process, without relying on subsequent composite processes.

[0056] Compared to existing technologies, traditional double-needle bed warp knitting processes use the same needle density and full yarn threading on both the front and back needle beds, resulting in symmetrical structures and a monotonous style on both sides. This solution, however, directly controls the yarn density of the observation layer 200 during the weaving stage by using the intermittent yarn threading method of the back needle bed guide bar, making its needle density only half that of the base layer 100. Simultaneously, the intervention of the back jacquard guide bar allows the observation layer 200 to dynamically adjust its structure, creating a visually distinct three-dimensional effect. This overcomes the technical limitation of traditional processes that require composite processing to achieve two-sided differences. This application achieves needle density differences and structural differentiation between the observation layer 200 and the base layer 100 in the same weaving process, avoiding the increased costs and reduced breathability associated with later composite processes. Through the synergistic effect of sparse needle density and jacquard weaving, the observation layer 200 forms a three-dimensional texture with alternating mesh and non-mesh patterns, while maintaining the overall softness and lightweight characteristics of the fabric.

[0057] Furthermore, the needle density of the substrate layer 100 is twice that of the observation layer 200. Preferably, the needle density of the substrate layer 100 is 24 needles, and the needle density of the observation layer 200 is 12 needles.

[0058] The base layer 100, with its high needle density, forms a dense fabric base, providing support strength and surface smoothness for the overall structure. The observation layer 200, with its low needle density, forms a coarse mesh structure, enhancing breathability while maintaining fabric thickness. This two-fold difference in needle density creates complementary physical properties between the base layer 100 and the observation layer 200 during weaving. The high-needle-density base layer 100 achieves continuous weaving through a full-thread yarn configuration, while the low-needle-density observation layer 200 forms a discrete mesh through intermittent yarn threading. The two layers are combined into a single structure during a single weaving process via connecting yarns 300. This approach avoids the traditional step of combining two fabrics with different needle densities, ensuring the stability of the double-sided structure through tension control. Specifically, in a specific embodiment of this application, the base layer 100 employs a 24-needle high-needle-density structure, increasing yarn density and forming a smooth and supportive base; the observation layer 200 employs a 12-needle low-needle-density structure, reducing the number of needles per unit area and creating larger mesh gaps. The difference in needle density between the two is achieved through independent parameter control of the front and rear needle beds. When Jacquard weave is filled in low needle density areas, the increased yarn spacing makes it easier to create a contrast between transparent and semi-transparent effects.

[0059] Advantageously, compared to existing technologies, traditional warp-knitted three-dimensional fabrics with the same needle density on both sides result in a symmetrical double-sided structure and a single function. This solution, however, uses a difference of twice the needle density to create a tighter and looser knitting pattern on the base layer 100 and the observation layer 200 respectively, directly forming an asymmetrical structure in a single weaving cycle. Furthermore, existing technologies require composite processes to achieve double-sided differentiation, which introduces adhesives and reduces fabric softness. This solution, on the other hand, directly weaves a double-sided differential density structure through the needle bed yarn feeding method, eliminating the need for additional processing steps.

[0060] Preferably, the yarn of the front needle bed comb is polyester DTY yarn.

[0061] Polyester DTY yarn refers to polyester fiber filaments produced through a stretching and deformation process. Specifically, it can be made from yarns of specifications such as 75D / 72F or 150D / 144F, exhibiting a stable crimped shape and uniform tensile resilience. During weaving, the cohesive force generated by its crimped structure effectively maintains the stability of the yarn's trajectory between the guide needles and knitting needles. The base layer 100, formed by the full-threaded yarn on the front needle bed comb, needs to bear the main stress of the overall fabric structure. The high tensile strength and low creep characteristics of polyester DTY yarn ensure that the base layer 100 maintains its morphological stability during weaving and subsequent processing.

[0062] Specifically, in a double-needle-bed warp knitting machine with a fully threaded front needle bed comb, the polyester DTY yarn generates a uniform yarn tension distribution through its unique crimp structure. When the needles move in loop formation at a high density, the yarn's elastic recovery characteristics compensate for the yarn stretching deformation caused by the reduced needle pitch during knitting, preventing yarn breakage or uneven loops due to excessive local tension. Simultaneously, the smoothness and antistatic properties of the yarn surface reduce the coefficient of friction between the yarn and the yarn guide during knitting, making yarn transport smoother in high-needle-density knitting. In the finishing stage, the heat-setting characteristics of the polyester DTY yarn allow the base layer 100 to maintain the preset loop structure during high-temperature treatment, preventing fabric deformation due to differences in heat shrinkage.

[0063] Beneficially, compared to existing technologies, traditional warp-knitted fabrics typically use ordinary polyester FDY or POY yarns as the ground comb material when using front and back needle beds with the same needle density. These yarns, lacking a crimp structure, are prone to yarn slippage or tension fluctuations during high-needle-density knitting, leading to a decrease in fabric surface smoothness. However, polyester DTY yarn, through its three-dimensional crimped shape and self-locking effect, can achieve stable high-density loop formation without increasing yarn friction damage. This overcomes the common processing bottleneck of conventional yarns when the needle pitch is reduced to 24 needles, enabling stable operation of the front needle bed ground comb under high-needle-density knitting conditions and ensuring that the base layer 100, as a load-bearing structure, possesses sufficient tensile strength and dimensional stability. The elastic recovery characteristics of the yarn effectively balance the tension difference between the front and back needle beds during knitting, avoiding overall fabric distortion caused by deformation of the base layer 100. Simultaneously, the thermoplastic properties of polyester DTY yarn allow the fabric to maintain its preset physical shape during finishing processes, providing reliable base support for subsequent composite processing with the observation layer 200.

[0064] Preferably, the yarn of the back Jacquard comb is cationic DTY yarn or polyester DTY yarn, and the yarn of the back needle bed ground comb GB5 and GB7 is polyester DTY yarn or cationic DTY yarn.

[0065] It should be noted that cationic DTY yarn refers to cationically modified polyester low-elasticity yarn, specifically achieved by using modified polyester filaments with high dye saturation values. It differs from ordinary polyester yarn in its dyeing rate. Polyester DTY yarn refers to unmodified polyester low-elasticity yarn, specifically achieved by using polyester fibers produced through conventional spinning processes, exhibiting high breaking strength and abrasion resistance. The choice of yarn material for the back Jacquard comb directly affects the color development and structural strength of the observation surface layer 200, while the choice of yarn material for the back needle bed ground combs GB5 and GB7 determines the mechanical properties and dyeing compatibility of the base surface layer 100.

[0066] Understandably, when cationic DTY yarn is used in the Houjaka comb, this yarn preferentially adsorbs anionic dyes during the dyeing process, creating a color difference with conventional polyester yarn. This results in a gradual or contrasting visual effect between the mesh and non-mesh areas of the observation surface 200. If polyester DTY yarn is used in the Houjaka comb, structural support is achieved by adjusting the weave density to ensure that the mesh shape does not deform during subsequent processing. When polyester DTY yarn is used in the back needle bed combs GB5 and GB7, the base surface 100 achieves higher tear resistance. When cationic DTY yarn is used, it is synchronously colored with the Houjaka comb yarn in the dyeing bath, avoiding color spot defects caused by differences in dye absorption. The cross-configuration of the two yarns between the longitudinal combs allows the fabric to maintain the continuity of the weave structure on both sides while achieving a differentiated design in terms of dyeing process compatibility and physical properties.

[0067] Compared to existing technologies, traditional double-needle bed combs typically use a single-material yarn, resulting in uniform dyeing on both sides of the fabric but lacking depth and exhibiting similar physical properties. Existing technologies require multi-layer lamination to achieve double-sided differentiation, leading to decreased interfacial bonding strength. This solution addresses the technical issues of monotonous double-sided style and functional homogenization in double-needle bed warp-knitted fabrics by using differentiated yarn materials between the longitudinal combs. This allows for the formation of double-sided functional zones in a single-layer fabric during the weaving stage, achieving differentiated dyeing effects and gradient distribution of mechanical properties without the need for subsequent lamination processes. The combined application of cationic and conventional polyester yarns creates a natural color transition zone on the observation layer 200 after dyeing, while the base layer 100 is made of a high-strength or easily dyeable material depending on the application requirements. This configuration maintains the overall structural integrity of the fabric while giving each side independent decorative and functional characteristics, and avoids the loss of breathability and environmental risks associated with multi-layer lamination processes.

[0068] Preferably, the semi-transparent fabric 230 is a thin gauze fabric, while the transparent fabric 240 is a mesh fabric.

[0069] It should be noted that the thin yarn weave refers to a semi-transparent structure formed by a specific yarn arrangement density. Specifically, it can be achieved by weaving together intermittently distributed looped yarns and weft yarns. The looped yarns form the basic mesh structure, while the weft yarns cover the mesh surface as partial floats. This structure, by controlling the ratio of the float coverage area to the open area of ​​the mesh, creates a scattering effect when light passes through, resulting in a uniform semi-transparent visual effect. The transparent weave 240 refers to a fabric structure that allows light to pass through and presents a transparent effect. Specifically, it can be achieved using a mesh structure composed of regularly arranged pores, with the light transmittance controlled by the size and distribution of the pores. The role of the mesh structure in the claims is that its porous structure, while maintaining the overall strength of the fabric, creates a density difference with the non-mesh portion 220, thereby enhancing the visual contrast of the viewing surface layer 200.

[0070] Specifically, when a thin fabric is combined with a mesh fabric, the aforementioned Jacquard fabric is (semi-transparent fabric 230) + (transparent fabric 240); When a mesh structure is combined with a thin yarn structure, it becomes the aforementioned Jacquard structure, which is (transparent structure 240) + (semi-transparent structure 230). When a thin fabric is combined with another thin fabric, it becomes the aforementioned Jacquard structure, which is (transparent fabric 230) + (transparent fabric 230). When mesh tissue is combined with mesh tissue, it becomes the aforementioned Jacquard tissue, which is (transparent tissue 240) + (transparent tissue 240).

[0071] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0072] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A method for weaving a warp-knitted three-dimensional fabric based on different needle densities in front and back, implemented using a double-needle bed warp knitting machine, characterized in that, The method comprises the following steps: Full-threading step: the front needle bed adopts full-threading yarn to form a base surface layer; Interval-threading step: the back needle bed adopts one-threading-and-one-empty-threading to form an observation surface layer, the observation surface layer and the base surface layer are connected through connecting yarns, the observation surface layer comprises mesh parts, non-mesh parts and jacquard structures, the jacquard structures are one or both of yarn-thin structures and mesh structures; Wherein, the needle density of the base surface layer is twice the needle density of the observation surface layer.

2. The method of weaving a warp-knitted three-dimensional fabric based on different needle densities in front and back according to claim 1, characterized in that, The needle density of the double-needle-bed warp knitting machine is 24 needles, in the full-threading step, the base surface layer forms a needle density of 24 needles, and in the interval-threading step, the observation surface layer forms a needle density of 12 needles.

3. The method of weaving a warp-knitted three-dimensional fabric based on different needle densities in front and back according to claim 2, characterized in that, In the interval-threading step, the back jacquard guide bar JB6-1 adopts the yarn spacing code 0-0-0-0 / 3-3-3-3 / / to form a yarn-thin structure, and the back jacquard guide bar JB6-2 adopts the yarn spacing code 0-0-0-0 / 2-2-2-2 / / to form a mesh structure.

4. The method of claim 3, wherein the warp knitting of the three-dimensional warp knitted fabric based on the different needle densities in the front and back is characterized by, The jacquard structure is any one of the following combinations: A, the jacquard structure is a yarn-thin structure + a mesh structure; B, the jacquard structure is a mesh structure + a yarn-thin structure; C, the jacquard structure is a yarn-thin structure + a yarn-thin structure; D, the jacquard structure is a mesh structure + a mesh structure.

5. The method of claim 1, wherein the warp-knitted three-dimensional fabric is formed by using different needle densities in front and back. In the full-threading step, the ground comb guide bar GB1 of the front needle bed adopts a warp pile structure, and the yarn spacing code is 1-0-1-1 / 2-3-3-3 / / , and the ground comb guide bar GB2 of the front needle bed adopts a warp flat structure, and the yarn spacing code is 1-2-1-1 / 1-0-1-1 / / .

6. The method of claim 1, wherein the warp-knitted three-dimensional fabric is formed by using different needle densities in front and back. In the interval-threading step, the ground comb guide bars GB5 and GB7 of the back needle bed form the mesh parts of the observation surface layer, the yarn spacing code of the GB5 is (2-2-1-0 / 0-0-2-3)*2 / (3-3-4-5 / 3-3-3-2)*2 / / 1-3 empty, and the yarn spacing code of the GB7 is (3-3-4-5 / 3-3-3-2)*2 / (2-2-1-0 / 0-0-2-3)*2 / / empty 3-1.

7. A fabric obtained by the weaving method according to any one of claims 1 to 6, characterized in that, It comprises: a base surface layer; an observation surface layer arranged above the base surface layer, the observation surface layer and the base surface layer are connected through connecting yarns, the observation surface layer comprises mesh parts, non-mesh parts and jacquard structures, the mesh parts and the non-mesh parts are arranged staggered along a first direction, and the mesh parts and the non-mesh parts are arranged staggered along a second direction, the first direction is perpendicular to the second direction, the jacquard structures are filled on the mesh parts and the non-mesh parts, the jacquard structures are arranged along the second direction, and the jacquard structures are one or both of yarn-thin structures and mesh structures; wherein, the needle density of the base surface layer is twice the needle density of the observation surface layer.

8. A fabric according to claim 7, characterised in that, The yarn of the ground comb guide bar of the front needle bed is polyester DTY yarn.

9. A fabric according to claim 7, wherein, The yarn of the back jacquard guide bar is cationic DTY yarn or polyester DTY yarn.

10. A fabric according to claim 7, wherein, The yarn of the ground comb guide bars GB5 and GB7 of the back needle bed is polyester DTY yarn or cationic DTY yarn.

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