Integrally-formed channel fabric suitable for multiple sizes and weaving method thereof

Abstract

The invention discloses an integrally-formed channel fabric adapting to multiple sizes and a weaving method thereof, and belongs to the technical field of spinning. A double-needle bar double-jacquard warp knitting machine is adopted, four half-machine-number jacquard combs are configured, specific basic yarn laying numerical codes are set, actual knitting structures of all areas are controlled in combination with jacquard offset signals, and five continuous structure areas with different functions are synchronously formed in the one-time knitting process; and the integrated elastic screen cloth with the concentric-square-shaped channel is formed. Integrated forming of the channel, the reinforcing edge, the side seam and the cutting guide line is achieved. The prepared fabric can be stretched and fixed to the required size only by cutting off the four corners and penetrating ropes or pipe fittings into the channels, has the remarkable advantages of no need of hemming, convenience in installation, high adaptability and high production efficiency, and is suitable for various scenes such as protection, sports, storage and the like.

Description

Technical Field

[0001] This invention belongs to the field of textile technology, and particularly relates to an integrally molded channel fabric adaptable to multiple sizes and its weaving method. Background Technology

[0002] Elastic mesh fabric, due to its excellent stretchability, breathability, and lightweight properties, is widely used in sports equipment, protective isolation, warehousing and storage, outdoor products, and medical aids. In these applications, it is often necessary to fix the edges or specific locations of the mesh fabric to form a specific shape and maintain a specific size.

[0003] The traditional approach involves first producing a flat, elastic mesh fabric, then cutting it to the required size. A cylindrical channel (or sleeve) is then sewn or glued to the edge of the mesh fabric using methods such as sewing, high-frequency heat sealing, or adhesive bonding. Finally, ropes, elastic cords, or rigid rods are threaded into this channel for fixation and tension. This post-processing method has several drawbacks: First, the sewing or gluing process is cumbersome, resulting in low production efficiency and high labor costs. Second, the seams or adhesive joints often become weak points in the fabric's mechanical structure, easily cracking due to stress concentration, affecting the product's lifespan. Third, the stitching marks affect the product's aesthetic appearance and may cause discomfort in applications involving skin contact. Finally, the traditionally produced channels have fixed dimensions, making it difficult to flexibly adapt to various installation size requirements, resulting in poor versatility.

[0004] To simplify the process, some technologies attempt to directly form tubular structures during weaving. For example, circular knitting can produce true cylindrical fabrics, but its structure is simple, making it difficult to combine local channels with large-area meshes on the same fabric. Furthermore, the products are usually of fixed diameter, failing to meet the requirements for edge channel fixation and planar unfolding. In the field of double-needle bed warp knitting, existing technologies mostly focus on forming uniformly spaced fabrics or simple geometric hollow structures. No technology has yet been found that can accurately and efficiently weave a complex, integrated structure on a single fabric, encompassing all four sides, possessing complete channel functions, and seamlessly integrating with other functional areas (such as high-strength seam edges and easy-to-cut edges).

[0005] Therefore, the industry urgently needs an innovative fabric structure design and production process that can fundamentally solve the above problems and achieve efficient, high-quality, and highly adaptable integrated manufacturing of channel elastic mesh fabric. Summary of the Invention

[0006] This invention proposes an integrated molded channel fabric adaptable to multiple sizes and its weaving method to solve the problems of uneven product structural strength and poor durability; to solve the problems of fixed product size and insufficient application flexibility; and to solve the problem of difficulty in integrated manufacturing of complex functional structures.

[0007] The core technical solution of this invention lies in: based on the characteristics of a double needle bed, four and a half Jacquard combs are configured, and through basic yarn padding digital data, combined with dynamic Jacquard offset signals, the yarn movement path is switched in real time at different spatial positions on the fabric, thereby forming five areas with completely different functions and structures on the fabric, realizing the integrated manufacturing of all functions from channels, reinforced edges to cutting lines.

[0008] The specific solution of the present invention is as follows: A knitting method for one-piece molded channel fabrics adaptable to multiple sizes, using a double-needle-bed double-jacq warp knitting machine, configured with a first jacquard guide bar and a second jacquard guide bar. The first jacquard guide bar includes two half-size jacquard guide bars JB2.1 and JB2.2, and the second jacquard guide bar includes two half-size jacquard guide bars JB3.1 and JB3.2. The method includes: Design a Jacquard pattern, defining five structural regions within the pattern, and configuring corresponding yarn padding codes and Jacquard offset signals for the four and a half machine-numbered Jacquard guide bars in each region. The five regions include: In region A, the first Jacquard comb and the second Jacquard comb are controlled to form circles on the front and rear needle beds, respectively, so that a double-layer mesh structure with front and rear layers is formed in this region; In region B, the four half-size Jacquard combs are controlled to periodically interlock and weave in a 2M horizontal row as one Jacquard weave cycle, so that the region forms a single-layer mesh structure with front and back connected; In region C, the four half-size Jacquard combs are controlled to alternately cross the needle bed in a one-alternate-one-row manner, so that a high-density sutured tension structure is formed in this region; In region D, the first Jacquard comb and the second Jacquard comb are controlled to form loops on the front and rear needle beds respectively, so that a chain structure with front and rear separation is formed in this region; In region E, JB2.1, JB3.1 and JB2.2, JB3.2 are controlled to form single-needle side sutures on the sides respectively; The warp knitting machine is controlled to perform integrated knitting, and the A, B, C, D and E regions are formed simultaneously during one knitting process, thereby obtaining a fabric with a loop-shaped tubular channel structure.

[0009] Furthermore, in region B, when cycling through 6 rows, In the Nth row, the first jacquard and the second jacquard respectively go to the opposite needle bed to knit into circles; In the N+1 and N+2 rows, the first jacquard and the second jacquard are still knitted into circles on the front and back needle beds, respectively; In the (N+3)th row, the first jacquard and the second jacquard respectively go to the opposite needle bed to knit into circles; In the N+4 and N+5 rows, the first jacquard and the second jacquard are still knitted into circles on the front and back needle beds, respectively.

[0010] Furthermore, in the C region, Both JB2.1 and JB2.2 are knitted in circles on the front needle bed, while on the back needle bed they are knitted in alternating rows, meaning one row forms a circle and the next row does not. Both JB3.1 and JB3.2 are knitted in circles on the back needle bed, while on the front needle bed they are knitted in alternating rows, meaning one row forms a circle and the next row does not.

[0011] Furthermore, the basic yarn padding numbers configured for the four and a half Jacquard combs are as follows: The JB2.1 and JB3.1 configurations are: 1-0-1-0 / 1-2-1-2 / / ; JB2.2 configuration is: 1-2-1-1 / 1-0-1-1 / / ; The JB3.2 configuration is: 1-1-1-2 / 1-1-1-0 / / .

[0012] Furthermore, the actual yarn padding numbers and corresponding offset signals of each comb bar in region A are as follows: JB2.1 Yarn padding code: 2-1-1-1 / 1-2-2-2 / / , Offset signal: TTHT HHTH; Yarn padding code: 2-1-1-1 / 2-3-2-2 / / , Offset signal: TTHT TTTH; Yarn padding code: 1-0-1-1 / 1-2-2-2 / / , Offset signal: HHHT HHTH; JB2.2 Yarn padding code: 1-2-2-2 / 2-1-1-1 / / , Offset signal: HHTT TTHH; Yarn padding code: 1-2-2-2 / 1-0-1-1 / / , Offset signal: HHTT HHHH; Yarn padding code: 2-3-2-2 / 2-1-1-1 / / , Offset signal: TTTT TTHH; JB3.1 Yarn padding code: 1-1-2-1 / 2-2-1-2 / / , Offset signal: HTTT THHH; Yarn padding code: 1-1-2-1 / 2-2-2-3 / / , Offset signal: HTTT THTT; Yarn padding code: 1-1-1-0 / 2-2-1-2 / / , Offset signal: HTHH THHH; JB3.2 Yarn padding code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT; Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , Offset signal: TTHH HHHH; Yarn padding code: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT.

[0013] Furthermore, the actual yarn padding numbers and corresponding offset signals of each guide bar in region B are as follows: JB2.1 Yarn padding code: 1-1-2-1 / 1-2-2-2 / / , Offset signal: HTTT HHTH; Yarn padding code: 2-1-1-1 / 2-3-2-2 / / , Offset signal: TTHT TTTH; Yarn padding code: 1-0-1-1 / 2-2-1-2 / / , Offset signal: HHHT THHH; JB2.2 Yarn padding code: 2-2-1-2 / 2-1-1-1 / / , Offset signal: THHT TTHH; Yarn padding code: 1-2-2-2 / 1-0-1-1 / / , Offset signal: HHTT HHHH; Yarn padding code: 2-3-2-2 / 1-1-2-1 / / , Offset signal: TTTT HTTH; JB3.1 Yarn padding code: 2-1-1-1 / 2-2-1-2 / / , Offset signal: TTHT THHH; Yarn padding code: 1-1-2-1 / 2-2-2-3 / / , Offset signal: HTTT THTT; Yarn padding code: 1-1-1-0 / 1-2-2-2 / / , Offset signal: HTHH HHTH; JB3.2 Yarn padding code: 1-2-2-2 / 1-1-2-1 / / , Offset signal: HTTH HHTT; Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , Offset signal: TTHH HHHH; Yarn padding code: 2-2-2-3 / 2-1-1-1 / / , offset signal: TTTT THHT.

[0014] Furthermore, the actual yarn padding numbers and corresponding offset signals of each comb bar in region C are as follows: JB2.1 Yarn padding code: 1-0-2-1 / 2-3-2-2 / / , Offset signal: HHTT TTTH; JB2.2 Yarn padding code: 2-3-1-2 / 1-0-1-1 / / , Offset signal: TTHT HHHH; JB3.1 Yarn padding code: 1-1-1-0 / 1-2-2-3 / / , Offset signal: HTHH HHTT; JB3.2 Yarn padding code: 2-2-2-3 / 2-1-1-0 / / , offset signal: TTTT THHH.

[0015] Furthermore, the actual yarn padding numbers and corresponding offset signals of each guide bar in region D are as follows: JB2.1 Yarn padding code: 2-1-1-1 / 1-2-2-2 / / , Offset signal: TTHT HHTH; JB2.2 Yarn padding code: 1-2-2-2 / 2-1-1-1 / / , Offset signal: HHTT TTHH; JB3.1 Yarn padding code: 1-1-2-1 / 2-2-1-2 / / , Offset signal: HTTT THHH; JB3.2 Yarn padding code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT.

[0016] Furthermore, the E region comprises two parts: the left and right side seams E1 and E2. The actual yarn padding numbers and corresponding offset signals for each guide bar in region E1 are as follows: JB2.1 Yarn padding code: 2-1-1-1 / 1-2-2-2 / / , Offset signal: TTHT HHTH; Yarn padding code: 2-1-1-1 / 2-2-1-2 / / , Offset signal: TTHT THHH; Yarn padding code: 1-0-1-1 / 1-2-2-2 / / , Offset signal: HHHT HHTH; JB3.1 Yarn padding code: 1-1-2-1 / 2-2-1-2 / / , Offset signal: HTTT THHH; Yarn padding code: 1-1-2-1 / 1-2-2-2 / / , Offset signal: HTTT HHTH; Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , Offset signal: THHH HTHH; The actual yarn padding numbers and corresponding offset signals for each guide bar in the E2 region are as follows: JB2.2 Yarn padding code: 1-2-2-2 / 2-1-1-1 / / , Offset signal: HHTT TTHH; Yarn padding code: 1-2-2-2 / 1-1-2-1 / / , Offset signal: HHTT HTTH; Yarn padding code: 2-3-2-2 / 2-1-1-1 / / , Offset signal: TTTT TTHH; JB3.2 Yarn padding code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT; Yarn padding code: 2-2-1-2 / 1-2-1-1 / / , Offset signal: TTHH HTHT; Yarn padding code: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT.

[0017] A one-piece molded channel fabric adaptable to multiple sizes, the fabric having a loop-shaped tubular channel structure; the fabric includes at least the following five one-piece woven structural areas: Area A has a double-layered elastic mesh structure with front and back layers, forming a cylindrical channel for inserting fasteners; Region B is a single-layer elastic mesh structure with interlocking front and back, connected to Region A covering its outer perimeter, forming the main body of the fabric; Region C consists of opposing sutures, connecting the front and rear layers of the double-layered elastic mesh structure in region A, and forming the high-strength suture edge of the tubular channel; Region D is a chain stitch structure with separate front and back sections, serving as a cutting area between adjacent fabrics; Region E is a single-needle side-suture suture tissue used for seamless suturing of the tubular channel.

[0018] The present invention has the following technical effects: By weaving in one go, fabrics with complete channels, reinforced edges, side seams, and cutting guide lines are directly formed, completely eliminating all subsequent processing steps such as cutting, sewing channels, and binding in traditional processes, and realizing continuous and automated production from yarn to finished product.

[0019] The channel and reinforced edges are formed by integral weaving of yarn without external stitches or adhesive layers, avoiding stress concentration points found in traditional processes. In particular, the "tight-stretch weave" in area C provides extremely high peel and tear resistance, making the channel edges strong and durable.

[0020] Achieving a truly seamless appearance, the various functional areas transition naturally through weaving, resulting in a smooth and flawless surface. The fabric is seamlessly integrated across all areas, eliminating the risk of loose threads or glue separation, ensuring overall structural stability and significantly extending product lifespan.

[0021] Thanks to the flexible mesh channel design in area A, users can easily stretch and secure the fabric to various desired sizes and shapes by threading in ropes or support rods of different lengths. This greatly expands the range of applications. Installation and disassembly are convenient; installation can be completed with just the simple steps of "cutting the corner, threading the rope, and stretching to secure," and disassembly is equally easy.

[0022] In summary, this invention solves a series of problems related to production efficiency, product performance, usage flexibility, and manufacturing cost of traditional channel mesh fabrics, and provides a high-performance, highly adaptable, innovative textile product and advanced manufacturing method. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of a one-piece molded channel fabric adaptable to multiple sizes according to the present invention; Figure 2 A schematic diagram of tissue circulation in region A, specifically JB2.1 and JB2.2. Figure 3 A schematic diagram of tissue circulation in region A, specifically JB3.1 and JB3.2. Figure 4 A schematic diagram of tissue circulation in region B, specifically JB2.1 and JB2.2. Figure 5 A schematic diagram of tissue circulation in region B, specifically JB3.1 and JB3.2. Figure 6 A schematic diagram of tissue circulation in region C, specifically JB2.1 and JB2.2. Figure 7 A schematic diagram of tissue circulation in region C, specifically JB3.1 and JB3.2. Figure 8 A schematic diagram of tissue circulation in regions D, specifically JB2.1 and JB2.2; Figure 9 A schematic diagram of tissue circulation in regions D, specifically JB3.1 and JB3.2; Figure 10 This is a schematic diagram of the JB2.1 tissue circulation in region E; Figure 11 This is a schematic diagram of the JB3.1 tissue circulation in region E; Figure 12 This is a schematic diagram of the JB2.2 tissue circulation in region E; Figure 13 This is a schematic diagram of the JB3.2 tissue circulation in region E. Detailed Implementation

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0025] In this specification, identical parts are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface" and "top surface," "inner" and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0026] Example 1 This invention provides a one-piece molded channel fabric adaptable to multiple sizes and its production method.

[0027] 1. Production equipment and raw materials Production is carried out using a double-needle-bed double-jacq warp knitting machine (such as RDPJ4 / 2), and the main technical parameters are as follows: Serial number: E24 Width: 140 inches Onboard security: 5 CPC Disconnection plate distance: 1 mm The four half-size Jacquard combs in the machine, namely JB2.1, JB2.2, JB3.1, and JB3.2, are activated. All four Jacquard combs are made of 2050 polyester-spandex core-spun yarn. This material combines the strength of polyester with the excellent elasticity of spandex, and the elastic recovery rate of the raw materials used in each comb is the same or similar, ensuring that the overall elasticity of the fabric is uniform.

[0028] Yarn feeding method: A coiled yarn feeding system is used to ensure uniform yarn tension and stable supply. Specifically, each Jacquard comb has 280 warp threads, and each comb is equipped with 6 coiled yarn feeds.

[0029] Threading method: For the four and a half gauge Jacquard combs JB2.1, JB2.2, JB3.1, and JB3.2, they respectively adopt the Jacquard threading methods of one-empty-one-thread and one-thread-one-empty, one-empty-one-thread and one-thread-one-empty. The specific configuration can be allocated according to the pattern design requirements to achieve fine jacquard effects and structural control.

[0030] 2. Weaving organizational structure and method The core of the present invention is to form five structurally distinct functional regions during a single weaving process through specific guide bar numbers and Jacquard control, jointly constituting an integrated fabric with a loop channel.

[0031] Basic guide bar number configuration Set the following basic guide bar numbers for the four Jacquard guide bars as the basic organizational structure for weaving: JB2.1: 1-0-1-0 / 1-2-1-2 / / ; JB2.2: 1-2-1-1 / 1-0-1-1 / / ; JB3.1: 1-0-1-0 / 1-2-1-2 / / ; JB3.2: 1-1-1-2 / 1-1-1-0 / / .

[0032] It should be noted that the above basic organization can adopt open coils, closed coils or a combination of both. The number of Jacquard organization repeat courses is 2M, where M takes odd values such as 1, 3, 5, 7, 9, etc., and can be adjusted according to product style and machine performance. For example, different Jacquard organization repeats such as 2 courses, 6 courses, 10 courses or 14 courses can be adopted.

[0033] Combined with Figure 1 , a specific description of the weaving of the five structurally distinct functional regions is as follows: Area A Area A forms the "loop" - shaped outer frame of the fabric of the present invention. This area is designed as a hollow cylindrical structure that is open on all four sides, forming a cavity that can be used to insert support / fixing objects such as ropes, elastic cords, plastic or metal rods, completely eliminating the step of sewing the hem in traditional processes. This area itself has an elastic mesh structure, enabling the channel to have axial stretchability, capable of adapting to inserted objects of different diameters and different stretching and fixing requirements of different sizes. This channel structure is directly formed during the weaving process rather than through post - processing, ensuring the integrity of the fabric structure and the uniformity of mechanical properties.

[0034] To achieve the hollow cylindrical structure, Area A adopts the "front and back needle bed grouped independent weaving" strategy: Front needle bed fabric layer: It is exclusively responsible for by two guide bars JB2.1 and JB2.2, and the movement of its yarn is strictly controlled within the range of the front needle bed and does not form loops with the back needle bed.

[0035] Back needle bed fabric layer: This layer is exclusively handled by two guide bars, JB3.1 and JB3.2, and its yarn movement is strictly controlled within the back needle bed area, without being knitted into the front needle bed.

[0036] Thus, the machine simultaneously weaves two pieces of elastic mesh fabric that are parallel in space but completely independent in structure. The gap between these two layers of fabric naturally forms the required tubular channel cavity.

[0037] To achieve the aforementioned separate weaving and form a specific elastic mesh, the movement of each guide bar in area A needs to be finely programmed. Different actual yarn padding numbers are invoked in the six horizontal cycles using Jacquard offset signals.

[0038] (1) Front needle bed knitting group (JB2.1 & JB2.2) This group of combs together forms the elastic mesh of the front needle bed (fabric surface layer). See the weave cycle below. Figure 2 .

[0039] JB2.1: Yarn padding digital 2-1-1-1 / 1-2-2-2 / / , offset signal TTHT HHTH (color #4); Yarn padding digital 2-1-1-1 / 2-3-2-2 / / , offset signal TTHT TTTH (color #12); Yarn padding digital 1-0-1-1 / 1-2-2-2 / / , offset signal HHHT HHTH (color #17); JB2.2: Yarn padding code: 1-2-2-2 / 2-1-1-1 / / , offset signal: HHTT TTHH (color #3); Yarn padding code: 1-2-2-2 / 1-0-1-1 / / , offset signal: HHTT HHHH (color #11); Yarn padding code: 2-3-2-2 / 2-1-1-1 / / , offset signal: TTTT TTHH (color No. 18).

[0040] (2) Back needle bed knitting group (JB3.1 & JB3.2) This group of combs constructs the elastic mesh of the back needle bed (the bottom layer of the fabric) in a completely independent and complementary manner. See the weave cycle below. Figure 3 .

[0041] JB3.1 Yarn padding code: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH (color #2); Yarn padding code: 1-1-2-1 / 2-2-2-3 / / , offset signal: HTTT THTT (color #39); Yarn padding code: 1-1-1-0 / 2-2-1-2 / / , Offset signal: HTHH THHH (color #40); JB3.2 Yarn padding code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT (color #1); Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , Offset signal: TTHH HHHH (color #36); Yarn padding code: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT (color No. 38).

[0042] Area B As the main load-bearing area of ​​the fabric, area B, while maintaining the same mesh appearance as area A, introduces regular cross-bed knitting movements to create a structural connection between the front and back needle bed fabric layers, and firmly connects the tubular channels around its periphery into a unified planar mesh.

[0043] When JB2.1 and JB2.2 are knitted only on the front or back needle bed, and JB3.1 and JB3.2 are knitted only on the back or front needle bed, the knitting pattern reverts to a "layered pattern" similar to that of Area A. This maintains the continuity of the mesh structure and the elasticity of the fabric.

[0044] When JB2.1 and JB2.2 perform "cross-bed knitting," meaning their yarns move to the back needle bed and complete loop formation, simultaneously, according to the "needle bed complementarity" principle, the back needle bed guide bars (JB3.1, JB3.2) move synchronously to the front needle bed and complete loop formation. At this point, the yarns of the front and back layers interlock at the crossing point, forming a strong "interlocking point."

[0045] In one possible embodiment, taking a 6-row cycle as an example, the first and second jacquards of the Nth row are knitted into circles on the opposite needle bed, and the first and second jacquards of the next N+1 and N+2 rows are still knitted into circles on the front and back needle beds, respectively. The first and second jacquards of the N+3th row are knitted into circles on the opposite needle bed, and the first and second jacquards of the N+4th and N+5th rows are still knitted into circles on the front and back needle beds, respectively.

[0046] Throughout the cycle, the knitting needle beds of JB2.1 / JB2.2 and JB3.1 / JB3.2 remain complementary. When the former is knitted on the front bed, the latter must be knitted on the back bed; when the former moves to the back bed, the latter must move to the front bed. This ensures the symmetry of the connection and the balance of the fabric structure.

[0047] To achieve the aforementioned periodic interlocking, a specific yarn-laying code needs to be invoked for each guide bar in a 6-column cycle using the Jacquard offset signal. Some of these codes are used to form interlocking points, while others are used to continue the mesh structure. See JB2.1 and JB2.2 for weave cycles. Figure 4 For JB3.1 and JB3.2 organizational cycles, see [link to JB3.1 and JB3.2]. Figure 5 .

[0048] The actual yarn padding numbers and corresponding offset signals for each guide bar in area B are as follows: JB2.1: Yarn padding code: 1-1-2-1 / 1-2-2-2 / / , offset signal: HTTT HHTH (color #48); Yarn padding code: 2-1-1-1 / 2-3-2-2 / / , Offset signal: TTHT TTTH (color #12); Yarn padding code: 1-0-1-1 / 2-2-1-2 / / , Offset signal: HHHT THHH (color #35); JB2.2 Yarn padding code: 2-2-1-2 / 2-1-1-1 / / , offset signal: THHT TTHH (color #32); Yarn padding code: 1-2-2-2 / 1-0-1-1 / / , offset signal: HHTT HHHH (color #11); Yarn padding code: 2-3-2-2 / 1-1-2-1 / / , Offset signal: TTTT HTTH (color #30); JB3.1 Yarn padding code: 2-1-1-1 / 2-2-1-2 / / , Offset signal: TTHT THHH (color #13); Yarn padding code: 1-1-2-1 / 2-2-2-3 / / , offset signal: HTTT THTT (color #39); Yarn padding code: 1-1-1-0 / 1-2-2-2 / / , offset signal: HTHH HHTH (color #41); JB3.2 Yarn padding code: 1-2-2-2 / 1-1-2-1 / / , offset signal: HTTH HHTT (color #15); Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , Offset signal: TTHH HHHH (color #36); Yarn padding code: 2-2-2-3 / 2-1-1-1 / / , offset signal: TTTT THHT (color No. 42).

[0049] Area C Region C is located at the edge of Region A (the cylindrical channel). As the "sealing" structure of the channel, it must have high peel strength and tear resistance to withstand the spreading force after ropes or pipes are inserted, repeated friction, and long-term use stress, avoiding stress concentration at the edge that could lead to damage. Its robustness is the fundamental guarantee for the practical application of the cylindrical channel in Region A, preventing the channel from delaminating or cracking during use.

[0050] Region C employs a high-frequency alternating cross-bed knitting technique to create a dense, anti-tightening structure. In each row of Region C, JB2.1 and JB2.2 are knitted into loops on the front needle bed, ensuring the continuity and integrity of the front needle bed knitting, while simultaneously knitting into loops on the back needle bed "every other row". JB3.1 and JB3.2 are also successfully knitted into loops on the back needle bed, ensuring the continuity and integrity of the back needle bed knitting, while simultaneously knitting into loops on the front needle bed "every other row". The cross-bed rows of the front and back needle beds interweave or overlap, forming a tight fit. Due to this design, in any given row of Region C, at least one set of guide bars is performing cross-bed knitting. This means that the front and back layers of fabric are connected together by at least one set of yarns in each row, with the yarns frequently shuttling and "pulling" against each other between the two layers, resulting in high seam strength in Region C.

[0051] To achieve the aforementioned high-frequency alternating cross-bed knitting, JB2.1 and JB2.2 are configured to knit loops on both the front needle bed and alternate rows on the back needle bed, meaning one row forms a loop and the next row does not. The weave cycle is as follows: Figure 6 As shown; JB3.1 and JB3.2 are both knitted into loops on the back needle bed, and similarly knitted in alternating rows on the front needle bed, with the weave cycle as follows. Figure 7 As shown.

[0052] The actual yarn padding numbers and corresponding offset signals for each guide bar in area C are as follows: JB2.1 Yarn padding code: 1-0-2-1 / 2-3-2-2 / / , Offset signal: HHTT TTTH (color #9); JB2.2 Yarn padding code: 2-3-1-2 / 1-0-1-1 / / , offset signal: TTHT HHHH (color #10); JB3.1 Yarn padding code: 1-1-1-0 / 1-2-2-3 / / , Offset signal: HTHH HHTT (color #6); JB3.2 Yarn padding code: 2-2-2-3 / 2-1-1-0 / / , offset signal: TTTT THHH (color No. 7).

[0053] Area D Region D is not part of the final product's functional structure but serves as an auxiliary design for the production process. It is located in the continuously woven greige fabric and acts as a spacer between two adjacent "hui"-shaped fabric units, as shown in Figure 1 the schematic position. Region D forms a strip-like structure with a loose structure and significantly lower strength than the functional area, providing a clear and easy-to-operate physical guiding line for subsequent separation processes. Along this area, the continuous greige fabric can be quickly and accurately cut or torn into individual products.

[0054] Region D adopts the "chain stitch organization", which is characterized by the coils being only connected in series longitudinally and having almost no lateral extension connection or extremely weak connection transversely. This makes the lateral strength of the fabric in this area very low and extremely easy to tear longitudinally. Configurations JB2.1 and JB2.2 are both knitted into loops on the front needle bed, and the stitch cycle is shown in Figure 8 ; JB3.1 and JB3.2 are both knitted into loops on the back needle bed, and the stitch cycle is shown in Figure 9 . Since the knitting on the front and back needle beds is completely independent, there is no connection between the surface and bottom layers of the fabric in this area.

[0055] The actual yarn laying numbers and corresponding offset signals of each guide bar in Region D are as follows: JB2.1 Yarn laying numbers: 2-1-1-1 / 1-2-2-2 / / , offset signal: TTHT HHTH (Color No. 4); JB2.2 Yarn laying numbers: 1-2-2-2 / 2-1-1-1 / / , offset signal: HHTT TTHH (Color No. 3); JB3.1 Yarn laying numbers: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH (Color No. 2); JB3.2 Yarn laying numbers: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT (Color No. 1).

[0056] Region E Region E is located at the left and right edges of the fabric, including the left and right side seams E1 and E2. It firmly connects the A regions of the "hui"-shaped fabric on the sides, making the entire fabric form a continuous tubular channel frame surrounding the four sides. The stitching area needs to maintain the same elastic mesh structure as the adjacent A regions to achieve a smooth transition in terms of vision, touch, and mechanical properties, achieving a "seamless" effect. The traditional side stitching process that needs to be carried out separately is eliminated.

[0057] Region E adopts single-sided stitching. Instead of using four guide bars to operate symmetrically on both sides simultaneously, specific guide bar pairs are assigned to complete high-quality edge closure on the designated side.

[0058] In region E1, taking a loop of 6 rows as an example, JB2.1 organizes the loop as follows: Figure 10 As shown, JB3.1 tissue circulation is as follows Figure 11 As shown.

[0059] The actual yarn padding numbers and corresponding offset signals for each guide bar in area E1 are as follows: JB2.1 Yarn padding code: 2-1-1-1 / 1-2-2-2 / / , offset signal: TTHT HHTH (color #4); Yarn padding code: 2-1-1-1 / 2-2-1-2 / / , Offset signal: TTHT THHH (color #13); Yarn padding code: 1-0-1-1 / 1-2-2-2 / / , Offset signal: HHHT HHTH (color #17); JB3.1 Yarn padding code: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH (color #2); Yarn padding code: 1-1-2-1 / 1-2-2-2 / / , offset signal: HTTT HHTH (color No. 48); Yarn padding code: 2-2-1-2 / 1-1-1-0 / / , offset signal: THHH HTHH (color No. 36).

[0060] In region E2, taking a cycle of 6 rows as an example, JB2.2 organizes the cycle as follows: Figure 12 As shown, JB3.2 tissue circulation is as follows Figure 13 As shown.

[0061] The actual yarn padding numbers and corresponding offset signals for each guide bar in region E2 are as follows: JB2.2 Yarn padding code: 1-2-2-2 / 2-1-1-1 / / , Offset signal: HHTT TTHH (color #3); Yarn padding code: 1-2-2-2 / 1-1-2-1 / / , offset signal: HHTT HTTH (color #15); Yarn padding code: 2-3-2-2 / 2-1-1-1 / / , offset signal: TTTT TTHH (color #18); JB3.2 Yarn padding code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT (color #1); Yarn padding code: 2-2-1-2 / 1-2-1-1 / / , offset signal: TTHH HTHT (color #34); Guide bar numbers: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT (color No. 38).

[0062] Embodiment 2 The present invention provides a one-piece formed channel fabric adaptable to multiple sizes, having a "return" - shaped planar configuration. Through unique structural design, three - dimensional solid channels and functional partitions are preset on a two - dimensional plane. The entire fabric can be clearly divided into five integrally connected regions according to structural differences and functional positions: Region A: A double - layer elastic mesh structure with front - and - back stratification Region A forms the outer frame of the "return" shape of the fabric. In the thickness direction, this region is composed of two independent and parallel elastic mesh fabric layers. There is no yarn connection between the two layers, forming a continuous hollow cavity surrounding the perimeter. Both the front and back layers are regular or irregular elastic meshes woven from polyester - spandex core - spun yarn. The mesh structure provides elasticity in the axial and transverse directions and ensures breathability. The hollow cavity serves as the preset channel, through which ropes, elastic cords, plastic or metal rods, etc. can be directly inserted for fixing, supporting or stretching the fabric, without any subsequent sewing and edging processes.

[0063] Region B: A single - layer elastic mesh structure with front - and - back interlocking Region B is located inside the "return" shape and is covered by the peripheral Region A, forming the main planar part of the fabric. In terms of thickness, this region is a single - layer but denser elastic mesh structure. It has the same mesh shape as Region A to achieve a seamless appearance. The difference is that the mesh structure in this region forms interlocking points at regular intervals (such as every few wales) in the longitudinal (weaving direction) through the regular cross - bed weaving of yarns, connecting the originally potentially separated front - and - back layer yarn systems into a whole. These interlocking points are evenly distributed, enhancing both the overall stiffness and dimensional stability of the fabric while retaining the basic elasticity of the mesh.

[0064] Region C: A pulling - against structure with front - and - back stitching Region C is located at the edge of Region A and adopts a "pulling - against structure". In this region, yarns shuttle and loop between the front and back needle beds at a high frequency (such as every other wale), causing the front and back layers of the fabric to be densely and alternately stitched together in this region, forming a reinforced edge similar to multiple lock stitches. The tissue structure is tight, with many yarn interweaving points, strong transverse tensile resistance and high peel strength. It prevents the inserted object from bursting or wearing the edge of the channel, ensuring the durability of the channel structure.

[0065] ​The D area is on the continuously produced grey fabric and is located between two adjacent "hui"-shaped units. The structure of this area is extremely sparse and weak, presenting a simple strip shape. It is composed of chain stitch tissues independently knitted by the front and rear needle beds. The chain stitch tissues are longitudinally looped, and there is almost no effective connection transversely, resulting in very low mechanical strength in this area, especially extremely weak transverse strength. The front and rear layers are completely separated here. As a preset "break point" or "cutting line", it guides precise and rapid cutting or tearing in subsequent processes, separating the continuous grey fabric into independent product units.

[0066] Area E: Single-needle side seam stitching tissue Area E includes the left and right side seams E1 and E2 of the fabric. This area stitches up the "hui"-shaped Area A on the side. In areas E1 and E2, a narrow and elastic stitching trace is woven respectively by specific comb bars (for example, JB2.1 of the front bed and JB3.1 of the rear bed are responsible for E1; JB2.2 of the front bed and JB3.2 of the rear bed are responsible for E2). The inside of this stitching trace is also a stretch mesh structure, but it is connected to Area A through precise knitting transition, making the side seam have no obvious bulge or seam trace macroscopically, achieving a "seamless" appearance. It completes the final closure of the fabric from plane to three-dimensional, forming a complete and surrounding tubular frame structure.

[0067] In the embodiments disclosed in this application, terms such as "install", "connect", "join", "fix", etc. should be understood in a broad sense. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "join" can be a direct connection or an indirect connection through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments disclosed in this invention can be understood according to specific circumstances.

[0068] The above are only the preferred embodiments of this application. It should be noted that for those of ordinary skill in the technical field, without departing from the principle of this application, several improvements and refinements can still be made, and these improvements and refinements should also be regarded as the protection scope of this application.

Claims

1. A weaving method for a one-piece molded channel fabric adaptable to multiple sizes, characterized in that... The application relates to a double-needle-bed double-jacquard warp knitting machine, which is configured with a first jacquard guide bar and a second jacquard guide bar, wherein the first jacquard guide bar comprises two half-gauge jacquard guide bars JB2.1 and JB2.2, and the second jacquard guide bar comprises two half-gauge jacquard guide bars JB3.1 and JB3.

2. The method comprises the following steps: a jacquard pattern is designed, five structure areas are defined in the pattern, and corresponding padding code and jacquard offset signals are configured for the four half-gauge jacquard guide bars in each area, wherein the five areas comprise: in the A area, the first jacquard guide bar and the second jacquard guide bar are controlled to form loops on the front needle bed and the back needle bed respectively, so that the area forms a double-layer mesh structure with front and back separation; in the B area, the four half-gauge jacquard guide bars are controlled to be periodically interlocked and knitted with 2M courses as a jacquard organization cycle, so that the area forms a single-layer mesh structure with front and back connection; in the C area, the four half-gauge jacquard guide bars are controlled to be alternately knitted across the needle bed with one course and one course, so that the area forms a high-density stitched interlock structure; in the D area, the first jacquard guide bar and the second jacquard guide bar are controlled to form loops on the front needle bed and the back needle bed respectively, so that the area forms a chain stitch structure with front and back separation; in the E area, JB2.1 and JB3.1 and JB2.2 and JB3.2 are controlled to form single-needle side seam stitching structures on the side edges; the warp knitting machine is controlled to be integrally knitted, and the A, B, C, D and E areas are synchronously formed in one knitting process, so that a fabric with a back-type cylindrical channel structure is obtained.

2. The braiding method of claim 1, wherein in the B area, when a 6-course cycle is used, in the Nth course, the first jacquard and the second jacquard are knitted to loops on the opposite needle bed respectively; in the N+1th and N+2th courses, the first jacquard and the second jacquard are still knitted to loops on the front needle bed and the back needle bed respectively; in the N+3th course, the first jacquard and the second jacquard are knitted to loops on the opposite needle bed respectively; in the N+4th and N+5th courses, the first jacquard and the second jacquard are still knitted to loops on the front needle bed and the back needle bed respectively.

3. The braiding method of claim 1, wherein in the C area, JB2.1 and JB2.2 are knitted to loops on the front needle bed and are knitted to one course and one course on the back needle bed, namely one course and one course; JB3.1 and JB3.2 are knitted to loops on the back needle bed and are knitted to one course and one course on the front needle bed, namely one course and one course.

4. The braiding method of claim 1, wherein the basic padding codes of the four half-gauge jacquard guide bars are as follows: JB2.1 and JB3.1 are configured as: 1-0-1-0 / 1-2-1-2 / / ; JB2.2 is configured as: 1-2-1-1 / 1-0-1-1 / / ; JB3.2 is configured as: 1-1-1-2 / 1-1-1-0 / / .

5. The braiding method of claim 4, wherein the actual padding codes and corresponding offset signals of the jacquard guide bars in the A area are as follows: JB2.1 padding code: 2-1-1-1 / 1-2-2-2 / / , offset signal: TTHT HHTH; padding code: 2-1-1-1 / 2-3-2-2 / / , offset signal: TTHT TTTH; Lapping code: 1-0-1-1 / 1-2-2-2 / / , offset signal: HHHT HHTH; JB2.2 Lapping code: 1-2-2-2 / 2-1-1-1 / / , offset signal: HHTT TTHH; Lapping code: 1-2-2-2 / 1-0-1-1 / / , offset signal: HHTT HHHH; Lapping code: 2-3-2-2 / 2-1-1-1 / / , offset signal: TTTT TTHH; JB3.1 Lapping code: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH; Lapping code: 1-1-2-1 / 2-2-2-3 / / , offset signal: HTTT THTT; Lapping code: 1-1-1-0 / 2-2-1-2 / / , offset signal: HTHH THHH; JB3.2 Lapping code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT; Lapping code: 2-2-1-2 / 1-1-1-0 / / , offset signal: TTHH HHHH; Lapping code: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT.

6. The braiding method of claim 4, wherein The actual lapping code and corresponding offset signal of each gilling bar in the B area are as follows: JB2.1 Lapping code: 1-1-2-1 / 1-2-2-2 / / , offset signal: HTTT HHTH; Lapping code: 2-1-1-1 / 2-3-2-2 / / , offset signal: TTHT TTTH; Lapping code: 1-0-1-1 / 2-2-1-2 / / , offset signal: HHHT THHH; JB2.2 Lapping code: 2-2-1-2 / 2-1-1-1 / / , offset signal: THHT TTHH; Lapping code: 1-2-2-2 / 1-0-1-1 / / , offset signal: HHTT HHHH; Lapping code: 2-3-2-2 / 1-1-2-1 / / , offset signal: TTTT HTTH; JB3.1 Lapping code: 2-1-1-1 / 2-2-1-2 / / , offset signal: TTHT THHH; Lapping code: 1-1-2-1 / 2-2-2-3 / / , offset signal: HTTT THTT; Lapping code: 1-1-1-0 / 1-2-2-2 / / , offset signal: HTHH HHTH; JB3.2 Lapping code: 1-2-2-2 / 1-1-2-1 / / , offset signal: HTTH HHTT; Lapping code: 2-2-1-2 / 1-1-1-0 / / , offset signal: TTHH HHHH; Lapping code: 2-2-2-3 / 2-1-1-1 / / , offset signal: TTTT THHT.

7. The braiding method of claim 4, wherein The actual lapping code and corresponding offset signal of each gilling bar in the C area are as follows: JB2.1 Lapping code: 1-0-2-1 / 2-3-2-2 / / , offset signal: HHTT TTTH; JB2.2 Lapping code: 2-3-1-2 / 1-0-1-1 / / , offset signal: TTHT HHHH; JB3.1 Lapping code: 1-1-1-0 / 1-2-2-3 / / , offset signal: HTHH HHTT; JB3.2 Lapping code: 2-2-2-3 / 2-1-1-0 / / , offset signal: TTTT THHH.

8. The braiding method of claim 4, wherein The actual lapping code and corresponding offset signal of each combing bar in the D area are as follows: JB2.1 Lapping code: 2-1-1-1 / 1-2-2-2 / / , offset signal: TTHT HHTH; JB2.2 Lapping code: 1-2-2-2 / 2-1-1-1 / / , offset signal: HHTT TTHH; JB3.1 Lapping code: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH; JB3.2 Lapping code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT.

9. The braiding method of claim 4, wherein The E area includes two parts of left and right side seams E1 and E2; The actual lapping code and corresponding offset signal of each combing bar in the E1 area are as follows: JB2.1 Lapping code: 2-1-1-1 / 1-2-2-2 / / , offset signal: TTHT HHTH; Lapping code: 2-1-1-1 / 2-2-1-2 / / , offset signal: TTHT THHH; Lapping code: 1-0-1-1 / 1-2-2-2 / / , offset signal: HHHT HHTH; JB3.1 Lapping code: 1-1-2-1 / 2-2-1-2 / / , offset signal: HTTT THHH; Lapping code: 1-1-2-1 / 1-2-2-2 / / , offset signal: HTTT HHTH; Lapping code: 2-2-1-2 / 1-1-1-0 / / , offset signal: THHH HTHH; The actual lapping code and corresponding offset signal of each combing bar in the E2 area are as follows: JB2.2 Lapping code: 1-2-2-2 / 2-1-1-1 / / , offset signal: HHTT TTHH; Lapping code: 1-2-2-2 / 1-1-2-1 / / , offset signal: HHTT HTTH; Lapping code: 2-3-2-2 / 2-1-1-1 / / , offset signal: TTTT TTHH; JB3.2 Lapping code: 2-2-1-2 / 1-1-2-1 / / , offset signal: TTHH HHTT; Lapping code: 2-2-1-2 / 1-2-1-1 / / , offset signal: TTHH HTHT; Lapping code: 2-2-2-3 / 1-1-2-1 / / , offset signal: TTTT HHTT.

10. A one-piece channel fabric of multiple sizes, woven according to the method of any one of claims 1 to 9, characterized in that The fabric has a back-shaped cylindrical channel structure; the fabric at least includes the following five structure areas woven and formed integrally: The A area is a double-layer elastic mesh structure with front and back layers, forming a cylindrical channel for fixing members; The B area is a single-layer elastic mesh structure with front and back interlocking, connected with the A area wrapped around its outer periphery, constituting the main body of the fabric; C zone, as the front and back stitching of the opposite pull tissue, connecting the front and back layered double-layer elastic mesh structure of the A zone, and forming the high-strength stitched edge of the tubular channel; D zone, as the front and back separated chain stitch, as the cutting area between adjacent fabrics; E zone, as the single needle side seam stitching, for stitching the tubular channel without seams.

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