Warp-knitted jacquard pile fabric production process

Abstract

The invention discloses a warp-knitted jacquard pile fabric production process, and relates to the technical field of pile fabric production. Comprising the steps of warp knitting jacquard treatment, production base material determination and pattern design and weaving parameter determination to obtain basic information. According to the method, the base cloth is subjected to regional division according to user requirements to obtain the texturing region, the non-texturing region and the edge region, and different regions of the base cloth are subjected to differentiation treatment, so that the production diversity of the pile fabric is improved, different production requirements of users can be conveniently met, and the production efficiency is improved through regional treatment. The influence on comfort and drapability caused by non-uniform velvet feeling and hand feeling, rough overall impression or too strong compaction feeling, and the imbalance of wearing experience and durability caused by the fact that the air permeability, the heat retention property, the moisture absorption and sweat releasing properties and other properties of different areas cannot be optimized can be avoided; whether the jacquard meets the standard or not is judged in an image matching mode, the quality of the woolen fabric is improved, and it is ensured that the woolen fabric meets user requirements.

Description

Technical Field

[0001] This invention relates to the field of velvet fabric production technology, specifically a warp-knitted jacquard velvet fabric production process. Background Technology

[0002] Warp-knitted jacquard fleece fabric is a high-end fabric based on warp-knitted structure and incorporating fleece technology. By forming complex jacquard patterns between the warp yarns and the parallel weft yarns, fleece is achieved in local areas or the fabric surface is kept smooth, thus combining rich texture, soft hand feel and good support.

[0003] Patent publication number CN120311390A discloses a warp-knitted pile fabric and its production process. The fabric includes a pile fabric body, with an upper pile material integrally formed on the upper surface and a lower pile material integrally formed on the lower surface. A multifunctional composite fabric is integrally formed inside the pile fabric body. The pile fabric body comprises recycled yarn, hollow fiber fabric, ultra-soft dense pile fabric, polyester yarn, and natural fiber fabric. The natural fiber fabric is located on the surface of the ultra-soft dense pile fabric, and the hollow fiber fabric is located on the surface of the natural fiber fabric. This invention describes a warp-knitted pile fabric and its production process. By reducing pre-treatment ironing and back-setting processes through dyeing, leveling agents, glacial acetic acid, and degreasing agents are added, along with a fleece enhancer, anti-wrinkle agent, and color-fixing agent. The pH value and oil content of the warp-knitted pile are adjusted and optimized, and the dyeing effect is enhanced by the leveling agent to meet standards.

[0004] Existing production processes for warp-knitted jacquard fleece fabrics mostly treat the fleece area, non-fleece area, and edge area uniformly, lacking control over differentiated processing. This results in uneven fleece feel and hand feel, and an overall rough appearance or excessive compaction, affecting comfort and drape. Edge areas often exhibit defects, wrinkles, or color differences due to tension and changes in the warp knitting structure, affecting the finished product's aesthetics and market competitiveness. Furthermore, the inability to optimize the breathability, warmth retention, and moisture wicking properties of different areas leads to an imbalance in wearing experience and durability. Therefore, this invention is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide a production process for warp-knitted jacquard fleece fabrics to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a production process for warp-knitted jacquard fleece fabric, wherein the production process includes the following steps:

[0007] Warp knitting jacquard processing is used to determine the production substrate, pattern design, and weaving parameters to obtain basic information. Based on this basic information, the substrate is processed by a warp knitting machine to obtain the base fabric.

[0008] The raw materials for production are determined, including napping materials, and are pre-treated according to production needs;

[0009] Once production parameters are determined, the amount of napping material to be used is determined based on user requirements to obtain target information, including target nap height and target density.

[0010] Regional distribution: Based on user needs, the base fabric is divided into three regions: flocked area, non-flocked area, and edge area. Different processing is then applied to the different regions of the base fabric.

[0011] The raw materials are combined to perform a napping treatment on the napping area of ​​the base fabric. Based on the target information, a napping material is selected and attached to the napping area of ​​the base fabric to obtain the finished product.

[0012] Defect identification involves obtaining a standard image of the floral design to obtain a reference image, obtaining an actual image of the floral design on the finished product to obtain a target image, setting judgment criteria, and determining whether the finished product is defective based on the reference image and the target image according to the judgment criteria.

[0013] Furthermore, during the pretreatment stage of the production raw materials, the napping materials are classified according to their different nap heights to obtain classification results, and temperature-sensitive or light-sensitive fibers are embedded in the classified napping materials.

[0014] Furthermore, the target amount of napping material is determined based on user needs: a reference catalog is established using a reference establishment method, user needs are matched based on the reference catalog to obtain matching results, the result information in the reference catalog is extracted based on the matching results to obtain matching information, a safety threshold is preset, the safety threshold is that the amount of napping material does not exceed 30% of the weight of the base fabric, the relationship between the target information and the safety threshold is judged to obtain the judgment result, and the matching information is adjusted based on the judgment result to obtain the target information.

[0015] Furthermore, the reference establishment method includes: obtaining past production information of warp-knitted jacquard fabrics to obtain past production information, which includes demand information and result information. The result information is the pile density and pile height used, and the demand information is the user's production demand. The correspondence between the result information and the demand information is established, and a reference directory is established to store the demand information, result information and correspondence.

[0016] Furthermore, the process of setting the judgment criteria is as follows: preset standard similarity, extract flower pattern features from the target image and reference image to obtain the target flower pattern and reference flower pattern, perform similarity matching based on the target flower pattern and reference flower pattern to obtain the target similarity, when the target similarity is less than the standard similarity, the finished product is a defective product, when the target similarity is greater than or equal to the standard similarity, the finished product is not a defective product.

[0017] Furthermore, the process of differentiated processing based on different areas of the base fabric includes separate processing of the flocked area, separate processing of the non-flocked area, and separate processing of the edge area.

[0018] Furthermore, the process of separately treating the velvet area is as follows: phase change microcapsules are implanted at the root of the velvet in the velvet area. The process of separately treating the non-velvet area is as follows: a micropore array is engraved in the non-velvet area, and a UV-cured transparent conductive polymer is used to fill part of the micropores. The pore structure is biomimetic to the surface of a lotus leaf and human sweat glands. The process of separately treating the edge area is as follows: TPU material is infiltrated into the base fabric in a gradient form to form a transition zone from the edge to the inside.

[0019] Furthermore, the napping material is made from recycled raw materials, and during the attachment stage, conductive yarns are added to the napped area and an enzymatic coating is applied to the non-nafted area.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] This warp-knitted jacquard fleece fabric production process involves dividing the base fabric into fleece-enhanced, non-fleece-enhanced, and edge zones based on user needs. This means dividing the base fabric into different zones according to user requirements and applying differentiated treatments to each zone. This enhances the versatility of fleece fabric production, facilitating responses to diverse user needs. Zoned processing avoids uneven fleece texture and hand feel, as well as rough overall appearance or excessive compaction, which can negatively impact comfort and drape. It also prevents the inability to optimize breathability, warmth, and moisture wicking properties in different zones, leading to inconsistent wearing experience and durability. Furthermore, a defect identification process, using image matching to determine if the jacquard pattern meets standards, further improves the quality of the fleece fabric, ensuring it meets user requirements.

[0022] Meanwhile, by establishing a reference method, information from previous production of fleece fabrics and user needs are used as a reference to determine the required fleece height and density based on user needs. Phase change microcapsules are implanted at the root of the fleece, and a precise distribution of 500-800 capsules per square centimeter is achieved through microfluidic electrostatic spraying, which can improve heat storage efficiency. By forming a microporous array, the pore structure is biomimetic to the surface of a lotus leaf and human sweat glands, which can improve breathability. TPU material penetrates into the fabric in a gradient form, forming a transition zone from the edge to the inside, which improves the user's wearing or use experience.

[0023] Meanwhile, recycled PET bottles are used to make napping fibers, i.e. napping materials, which embody green environmental protection. During the attachment stage, if conductive yarns are added to the napped area and an enzymatic coating is applied to the non-nafted area, regionalized functions and sensing effects can be achieved: the conductive yarns in the napped area provide conductive paths for local sensing, touch feedback, or smart wearable applications, enhancing interactivity and sensing capabilities; the enzymatic coating in the non-nafted area controls the surface properties, breathability, and protective performance of the area boundary through selective degradation or material modification, while reducing friction between the napped and non-nafted areas, improving overall durability and washing stability. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall process structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the base fabric structure of the present invention;

[0026] Figure 3 This is a schematic diagram of the defect detection structure of the present invention. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Warp-knitted jacquard fleece fabrics, due to their rich surface fleece texture, clear layering, and controllable regional properties, are widely used in high-end apparel (such as outerwear, coats, linings for jackets, formal wear, and highlight items in sportswear and casual wear collections), home textiles (bedding, cushions, sofa covers, and other items requiring tactile and visual depth), and high-end crafts and gift textiles. In practice, they can also be used in automotive interiors, hotel fabrics, and functional fabrics for aviation / outdoor equipment. Through regional fleece application and control of breathability and warmth, comfort, durability, and aesthetics can be improved. Appropriate fleece application strategies and finishing processes need to be selected based on the target market and usage environment.

[0029] like Figures 1-3 As shown, the present invention provides a technical solution: a production process for warp-knitted jacquard fleece fabric, the production process including the following steps:

[0030] Warp knitting jacquard processing is used to determine the production substrate, pattern design, and weaving parameters to obtain basic information. Based on this basic information, the substrate is processed by a warp knitting machine to obtain the base fabric.

[0031] It is important to note that determining the pattern design and weaving parameters is essential to obtaining basic information, such as the pattern, needle path, warp / weft yarn combination, tension, and machine speed parameters. The specific process involves simultaneously weaving the jacquard fabric using ground yarn and pattern yarn on a warp knitting machine.

[0032] The raw materials for production are determined, including napping materials, and are pre-treated according to production needs;

[0033] It is important to note that the bottom layer is the base material for flocking, while the raising material is an auxiliary material. Raising materials include short-fiber materials, flock particles / short-fiber granules, and fiber / blended flocks, etc. The appropriate raising material is selected based on the specific application. For example, short-fiber materials: short fibers used directly as the flock layer, commonly found in flock layers of bonding, hot-melt, or laminating processes; commonly used materials: polyester (polyester) short fibers, polypropylene (PPI), nylon, etc.; characteristics: controllable flock length, high softness, strong fluffiness, easy to bond with the base fabric. Before producing warp-knitted jacquard flock fabrics, the base fabric needs to undergo tension optimization and pre-treatment positioning to achieve the desired effect. To ensure clear zone boundaries and uniform napping, the following steps are taken: cleaning and removing oil stains from the base fabric, combing and oriented the fabric to ensure stable warp and weft yarn tension; surface treatment of the napping material (such as cleaning, adhesion enhancement, or coating preparation) to improve adhesion for bonding or lamination; conducting compatibility assessments between the base fabric and the napping material, and performing surface modification (such as plasma treatment or applying an undercoat adhesive) if necessary to improve bonding strength and boundary control of regional napping; and simultaneously evaluating the process parameters of the samples (pile thickness, bonding temperature / time, zone coverage method, etc.) to ensure the stability of the finished product and the controllability of subsequent finishing processes.

[0034] Once production parameters are determined, the amount of napping material to be used is determined based on user requirements to obtain target information, including target nap height and target density.

[0035] It is important to note that the process of determining the amount of napping material to obtain target information based on user needs involves deciding the amount of napping material in the napping zone based on the user's usage requirements. The amount of napping material is used as an auxiliary measure to ensure the heat insulation performance of the fleece fabric.

[0036] Regional distribution: Based on user needs, the base fabric is divided into three regions: flocked area, non-flocked area, and edge area. Different processing is then applied to the different regions of the base fabric.

[0037] It is important to note that the process of dividing the base fabric into areas such as fleece-covered, non-fleece-covered, and edge areas based on user needs involves dividing the base fabric into different zones according to user requirements and treating each zone differently. This enhances the user experience of fleece fabrics and facilitates meeting diverse production needs. By treating these zones separately, it is possible to avoid uneven fleece texture and feel, as well as a rough overall appearance or excessive compaction that could negatively impact comfort and drape. It also helps to prevent the inability to optimize the breathability, warmth, and moisture-wicking properties of different zones, which could lead to uneven wearing experience and durability.

[0038] The raw materials are combined to perform a napping treatment on the napping area of ​​the base fabric. Based on the target information, a napping material is selected and attached to the napping area of ​​the base fabric to obtain the finished product.

[0039] It is important to note that during the flocking process, the base fabric must first be cleaned, combed, and tension-set to ensure stable warp and weft tension and clear boundaries. The geometry and boundaries of the flocking area must be clearly defined on the base fabric, usually through masking, partitioning, or shielding. For each area of ​​flocking, a suitable method (spinning, brushing, hot-melt flocking, adhesive flocking, laminated flocking, etc.) should be selected, and the thickness / density should be adjusted. Flocking and jacquard are performed in stages, and the order is usually: first, the regional pattern base fabric is woven, and then the required areas are flocked. Alternatively, flocking can be performed first and then jacquard, but the key point is to ensure that the area boundaries, adhesion, and fabric tension remain stable at each stage.

[0040] Defect identification involves obtaining a standard image of the floral design to obtain a reference image, obtaining an actual image of the floral design on the finished product to obtain a target image, setting judgment criteria, and determining whether the finished product is defective based on the reference image and the target image according to the judgment criteria.

[0041] It is important to note that the defect identification process, which uses image matching to determine whether jacquard fabrics meet standards, improves the quality of fleece fabrics and ensures that they meet user needs.

[0042] In the pretreatment stage of production raw materials, the napping materials are classified according to different nap heights to obtain classification results, and temperature-sensitive or light-sensitive fibers are embedded in the classified napping materials.

[0043] It's important to note that the process of classifying napped materials based on their pile height provides information on the pile height, facilitating the selection of materials with different pile heights for transplantation. Embedding temperature-sensitive or light-sensitive fibers into napped materials can achieve an environmentally responsive appearance and wearing experience: temperature-sensitive fibers can change the feel, fluffiness, or color at different temperatures, enhancing warmth and visual appeal; light-sensitive fibers can change color, brightness, or texture when light intensity changes, enhancing interactivity and visibility, suitable for decorative designs or functional cues. In practical applications, washing stability, processing compatibility, and boundary control need to be considered based on the usage scenario to ensure long-term durability and consistency.

[0044] The target amount of napping material is determined based on user needs: a reference catalog is established using a reference establishment method, and the user needs are matched based on the reference catalog to obtain matching results. The result information in the reference catalog is extracted based on the matching results to obtain matching information. A safety threshold is preset, which is that the amount of napping material does not exceed 30% of the weight of the base fabric. The relationship between the target information and the safety threshold is judged to obtain the judgment result. The matching information is adjusted based on the judgment result to obtain the target information.

[0045] It is important to note that in the production of warp-knitted jacquard fleece fabrics, the pile-raising material can be used as both a primary and auxiliary material. The auxiliary material is used to fill and maintain the pile density after processes such as napping and brushing the base fabric. The primary material is used for hot-melt fleece, bonded fleece, and coated fleece. Directly transferring the pile-raising material onto the base fabric as the primary material facilitates control over the fleece fabric's insulation performance. By setting a preset safety threshold that the amount of pile-raising material does not exceed 30% of the base fabric weight, it is possible to ensure a balance between the weight and breathability of the fleece area and the base fabric. This avoids excessive weight gain that leads to stiffness, decreased body fit, and poor washing stability, while also reducing the impact on the structural strength of the base fabric, improving durability and service life. It also facilitates process control and cost accounting, reduces material waste, and achieves more stable regional fleece boundaries and consistency in large-scale production. The specific safety threshold can be adjusted according to actual usage.

[0046] The reference establishment method includes: obtaining past production information of warp-knitted jacquard fabrics, which includes demand information and result information. The result information is the pile density and pile height used, and the demand information is the user's production demand. The correspondence between the result information and the demand information is established, and a reference directory is established to store the demand information, result information and correspondence.

[0047] It is important to note that by using the reference establishment method, information from previous production of fleece fabrics and user needs are used as a reference to determine the required fleece height and density based on user requirements. For example, when the primary requirement is warmth, the fleece density is 1800-2200 (threads / cm²). 2 The pile height is 3.5-5.0 mm. When the main requirements are high abrasion resistance and lightweight, the pile density is 800-1200 (heads / cm). 2 The pile height is 0.8–1.2 mm. When the primary requirement is breathability and antibacterial properties, the pile density is 1500–1800 (heads / cm). 2 The pile height is 1.5–2.0 (mm).

[0048] like Figure 3 As shown, the process of setting the judgment criteria is as follows: preset standard similarity, extract flower pattern features from the target image and reference image to obtain the target flower pattern and reference flower pattern, perform similarity matching based on the target flower pattern and reference flower pattern to obtain the target similarity, when the target similarity is less than the standard similarity, the finished product is a defective product, when the target similarity is greater than or equal to the standard similarity, the finished product is not a defective product.

[0049] It is important to note that the standard similarity is determined based on the actual situation. The higher the standard similarity value, the higher the quality of the finished product. The process of extracting flower pattern features from the target image and the reference image to obtain the target flower pattern and the reference flower pattern, and performing similarity matching based on the target flower pattern and the reference flower pattern to obtain the target similarity, is the process of feature extraction and similarity matching. The logic for determining whether the finished product is defective is to judge the relationship between the similarity of the finished product's flower pattern and the standard flower pattern and the standard similarity.

[0050] like Figure 1 As shown, the process of differentiated processing based on different areas of the base fabric includes separate processing of the flocked area, separate processing of the non-flocked area, and separate processing of the edge area.

[0051] It is worth noting that by processing different areas separately, the quality of fleece fabric production can be improved, and it is also easier to meet the needs of different users.

[0052] The process of treating the velvet area separately is as follows: phase change microcapsules are implanted at the root of the velvet in the velvet area. The process of treating the non-velvet area separately is as follows: micropore arrays are engraved in the non-velvet area, and UV-cured transparent conductive polymer is used to fill part of the micropores. The pore structure is biomimetic to the surface of lotus leaves and human sweat glands. The process of treating the edge area separately is as follows: TPU material is infiltrated into the base fabric in a gradient form to form a transition zone from the edge to the inside.

[0053] It is important to note that phase change microcapsules (PCM, melting point 28℃ / 35℃ dual temperature range) are implanted at the root of the villi. A precise distribution of 500-800 capsules per square centimeter is achieved through microfluidic electrostatic spraying, enhancing heat storage efficiency. Picosecond laser engraving (wavelength 355nm) forms a micropore array with a diameter of 20-50μm. UV-cured transparent conductive polymer (PEDOT:PSS) fills some of the micropores. The pore structure is biomimetic to the surface of a lotus leaf (contact angle 162°) and resembles human sweat glands (breathability 4500g / m²). 2 ( / 24h), conductive network sheet resistance ≤10Ω / sq, compatible with EMI shielding requirements, improves breathability and surface resistance, adopts supercritical CO2 assisted hot melting, so that TPU material penetrates into the fabric in a gradient form, forming a 0.5-2mm transition zone from the edge to the inside, and the modulus gradually changes from 200MPa to 5MPa, improving the user's wearing or use experience.

[0054] The napping material is made from recycled raw materials. During the attachment stage, conductive yarns are added to the napped area, and an enzymatic coating is applied to the non-nafted area.

[0055] It is important to note that recycling PET bottles to produce napping fibers, i.e. napping materials, embodies green environmental protection. During the attachment stage, if conductive yarns are added to the napped areas and an enzymatic coating is applied to the non-nafted areas, regionalized functions and sensing effects can be achieved: the conductive yarns in the napped areas provide conductive paths for localized sensing, touch feedback, or smart wearable applications, enhancing interactivity and sensing capabilities; the enzymatic coating in the non-nafted areas, through selective degradation or material modification, controls the surface properties, breathability, and protective performance of the area boundaries, while reducing friction between the napped and non-nafted areas, improving overall durability and washing stability.

[0056] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art 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 appended embodiments and their equivalents.

Claims

1. A production process for warp-knitted jacquard fleece fabric, characterized in that, The production process includes the following steps: Warp knitting jacquard processing is used to determine the production substrate, pattern design, and weaving parameters to obtain basic information. Based on this basic information, the substrate is processed by a warp knitting machine to obtain the base fabric. The raw materials for production are determined, including napping materials, and are pre-treated according to production needs; Once production parameters are determined, the amount of napping material to be used is determined based on user requirements to obtain target information, including target nap height and target density. Regional distribution: Based on user needs, the base fabric is divided into three regions: flocked area, non-flocked area, and edge area. Different processing is then applied to the different regions of the base fabric. The raw materials are combined to perform a napping treatment on the napping area of ​​the base fabric. Based on the target information, a napping material is selected and attached to the napping area of ​​the base fabric to obtain the finished product. Defect identification involves obtaining a standard image of the floral design to obtain a reference image, obtaining an actual image of the floral design on the finished product to obtain a target image, setting judgment criteria, and determining whether the finished product is defective based on the reference image and the target image according to the judgment criteria.

2. The production process of warp-knitted jacquard fleece fabric according to claim 1, characterized in that: In the pretreatment stage of production raw materials, the napping materials are classified according to different nap heights to obtain classification results, and temperature-sensitive or light-sensitive fibers are embedded in the classified napping materials.

3. The production process of warp-knitted jacquard fleece fabric according to claim 1, characterized in that: The target amount of napping material is determined based on user needs: a reference catalog is established using a reference establishment method, and the user needs are matched based on the reference catalog to obtain matching results. The result information in the reference catalog is extracted based on the matching results to obtain matching information. A safety threshold is preset, which is that the amount of napping material does not exceed 30% of the weight of the base fabric. The relationship between the target information and the safety threshold is judged to obtain the judgment result. The matching information is adjusted based on the judgment result to obtain the target information.

4. The production process of warp-knitted jacquard fleece fabric according to claim 3, characterized in that: The reference establishment method includes: obtaining past production information of warp-knitted jacquard fabrics, which includes demand information and result information. The result information is the pile density and pile height used, and the demand information is the user's production demand. The correspondence between the result information and the demand information is established, and a reference directory is established to store the demand information, result information and correspondence.

5. The production process of warp-knitted jacquard fleece fabric according to claim 1, characterized in that: The process of setting the judgment criteria is as follows: preset standard similarity, extract flower pattern features from the target image and reference image to obtain the target flower pattern and reference flower pattern, perform similarity matching based on the target flower pattern and reference flower pattern to obtain the target similarity, when the target similarity is less than the standard similarity, the finished product is a defective product, when the target similarity is greater than or equal to the standard similarity, the finished product is not a defective product.

6. The production process of warp-knitted jacquard fleece fabric according to claim 1, characterized in that: The process of differentiated processing based on different areas of the base fabric includes separate processing of the flocked area, separate processing of the non-flocked area, and separate processing of the edge area.

7. The production process of warp-knitted jacquard fleece fabric according to claim 6, characterized in that: The process of treating the velvet area separately is as follows: phase change microcapsules are implanted at the root of the velvet in the velvet area. The process of treating the non-velvet area separately is as follows: micropore arrays are engraved in the non-velvet area, and UV-cured transparent conductive polymer is used to fill part of the micropores. The pore structure is biomimetic to the surface of lotus leaves and human sweat glands. The process of treating the edge area separately is as follows: TPU material is infiltrated into the base fabric in a gradient form to form a transition zone from the edge to the inside.

8. The production process of warp-knitted jacquard fleece fabric according to claim 1, characterized in that: The napping material is made from recycled raw materials, and during the attachment stage, conductive yarns are added to the napping area and an enzymatic coating is applied to the non-nailing area.

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