Knitting process of towel imitation jean fabric

Abstract

The weaving process of the towel imitation jean fabric is characterized in that the towel imitation jean fabric comprises a plurality of weaving lines; each weaving row at least comprises loop yarns and ground yarns, and a plurality of weaving rows are used as basic weaves for circular weaving; in each base weave, the loop yarn and the ground yarn form loops together, and the loop yarn forms a pile loop higher than the loops at least between one adjacent loop; according to the technical scheme, the classic texture style of the jean fabric is reserved, meanwhile, the fabric has good air permeability and elastic recovery capacity, and the application scene of the jean fabric is remarkably widened.

Description

Technical Field

[0001] This application relates to the field of textile technology, specifically to a weaving process for a terry cloth imitation denim fabric. Background Technology

[0002] Denim is a classic clothing fabric, consistently favored by the market and consumers for its durability, stretch resistance, and crispness in garments. Furthermore, its versatility across seasons and wide applicability ensure a promising future for denim. However, with technological advancements, consumers are no longer satisfied with the existing characteristics of denim and desire advantages such as elasticity, breathability, and a comfortable fit. Currently, most denim fabrics on the market are produced on looms, which, due to technological limitations, result in fabrics that are not breathable, lack elasticity, and tend to have a stiff, rugged style. Therefore, developing a weft-knitted denim-like fabric is crucial to meeting customers' higher quality demands for denim. Summary of the Invention

[0003] In view of the above problems, this application provides a weaving process for a towel-like denim fabric, which solves the problems of existing denim fabrics being non-breathable and lacking elasticity.

[0004] To achieve the above objectives, the inventors provide a weaving process for a terry cloth imitation denim fabric, wherein the terry cloth imitation denim fabric includes several rows; each row includes at least loop yarn and base yarn, and is woven in a circular pattern based on several weave rows; in each basic pattern, the loop yarn and the base yarn together form loops, and the loop yarn forms loops higher than the loops at least between adjacent loops; the loops of several rows are arranged correspondingly to form continuous loop stripes.

[0005] Furthermore, the terry stripes are longitudinal stripes or diagonal stripes.

[0006] Furthermore, the loop yarn forms loops higher than the loops between adjacent loops.

[0007] Furthermore, each row is a cyclical weave based on four weave columns.

[0008] Furthermore, the terry-like denim fabric is composed of four rows arranged in a circular pattern; loops are formed between the first and second weave columns in the basic structure of the first row; loops are formed between the second and third weave columns in the basic structure of the second row; loops are formed between the third and fourth weave columns in the basic structure of the third row; and loops are formed between the fourth weave column in the basic structure of the fourth row and the first weave column of the next basic structure.

[0009] Furthermore, the shrinkage rate of the base yarn is 12-15%.

[0010] Furthermore, the loop yarn is a 150D-200D composite yarn; the base yarn is a 100D-150D composite yarn.

[0011] Furthermore, the loops are formed using a terry loop machine; the loops are formed by pushing out the loop yarn between the two adjacent loops through a sinker when forming two adjacent loops, so that the loop yarn between the two adjacent loops is stretched.

[0012] Furthermore, the nose height of the settling plate is 1.2-1.5 mm.

[0013] Furthermore, the length of the loop yarn with 100 needles is 35-38cm, and the length of the base yarn with 100 needles is 30-32cm.

[0014] Unlike existing technologies, each row of the above-mentioned technical solution is woven in a cyclic pattern using a basic structure. Loops are formed through the coordinated looping of the loop yarns and the base yarns within the basic structure, creating loops higher than the loops between adjacent loops. These loops, arranged in corresponding patterns across several rows, form a continuous terry stripe. This design, where loop yarns and base yarns work together to form loops, enhances the fabric's breathability and improves wearing comfort by utilizing the natural gaps between the loops. Furthermore, the double-yarn loop structure of the loop yarns and base yarns provides the fabric with excellent elastic recovery, meeting the needs of human movement. The continuous terry stripe retains the classic texture of denim fabric while creating a unique visual and tactile experience through the three-dimensional protrusion of the loops. This optimizes the fabric's practical performance while enriching its decorative effect, significantly expanding the application scenarios of denim fabric.

[0015] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0016] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of the present invention and other related contents, and should not be considered as limitations on this application.

[0017] In the accompanying drawings of the instruction manual:

[0018] Figure 1 This is a schematic diagram of the structure of the towel-like denim fabric described in a specific embodiment. Detailed Implementation

[0019] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0020] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0021] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0022] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0023] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0024] Without further limitations, the use of terms such as “comprising,” “including,” “having,” or other similar open-ended expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0025] As understood in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0026] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0027] The processor described in the embodiments of this application can be implemented by hardware, firmware, software, or a combination thereof. It can be a circuit, one or more of an application-specific integrated circuit (ASIC), a digital signal processor (DSP), a digital signal processing device (DSPD), a programmable logic device (PLD), a field-programmable gate array (FPGA), a central processing unit (CPU), a controller, a microcontroller, or a microprocessor. It also includes other physical, biological, or chemical structures that can implement the same or equivalent functions as the processors listed above, such as biological neurons, quantum computing units, DNA computing units, etc., so that the processor can execute some or all of the steps in the computer program or method involved in the various embodiments of this application, or any combination of the steps mentioned therein.

[0028] The computer program involved in the embodiments can be stored in a computer device readable storage medium, which includes, but is not limited to, disks, magnetic tapes, magnetic cards, floppy disks, flash memory, optical disks, optical cards, read-only memory (ROM), random access memory (RAM), erasable programmable ROM (EPROM), and electrically erasable programmable ROM (EEPROM), etc., and also includes other biological, physical, or chemical structures that can achieve the same or equivalent functions as the storage media listed above, such as DNA, RNA, proteins, and other units with information storage capabilities. In specific embodiments, the storage medium involved can be one of the above-mentioned media types, or a combination of the above-mentioned media types. In different embodiments, the computer program involved in the embodiments can be centrally stored in a single medium, or distributed and stored in multiple media. The memory containing the computer device readable storage medium can be non-volatile memory or random access memory. These computer device readable storage media can be built into the device, or can be connected to the device involved in the embodiments as an external device or part of an external device. In some embodiments, the memory having a computer device readable storage medium is deployed locally; in other embodiments, the memory may be deployed remotely from the processor, for example, as a network-attached memory accessed via RF circuitry or an external port and a communication network, wherein the communication network may be the Internet, one or more intranets, a local area network (LAN), a wide area network (WLAN), a storage area network (SAN), or a suitable combination thereof, as long as computer device access to the memory is enabled. Furthermore, the computer program involved in the embodiments may be stored in plaintext / ciphertext form, or it may be designed as training data, integrated and recombined through model training and implicitly stored in the parameter states of a deep neural network or other machine learning model.

[0029] A weaving technique for a denim-like towel fabric is described, in which each row is woven in a basic structure. Loops are formed by the cooperation of loop yarns and base yarns within the basic structure, creating loops higher than the loops between adjacent loops. These loops, arranged in corresponding patterns over several rows, form a continuous terry stripe. This design, where loop yarns and base yarns work together to form loops, enhances the fabric's breathability and improves wearing comfort by utilizing the natural gaps between the loops. Furthermore, the double-yarn loop structure of the loop and base yarns provides the fabric with excellent elasticity, meeting the needs of human movement. The continuous terry stripe retains the classic texture of denim fabric while creating a unique visual and tactile experience through the three-dimensional protrusion of the loops. This optimizes the fabric's practicality while enriching its decorative effect, significantly expanding the application scenarios of denim fabric.

[0030] Combination Figure 1As shown, an implementation process for weaving a terry fabric imitating denim is provided. The terry fabric imitating denim includes several rows; each row includes at least loop yarn and base yarn, and is woven in a circular pattern based on several weave rows; in each basic pattern, the loop yarn and the base yarn are looped together to form a loop, and the loop yarn forms a loop higher than the loop at least between an adjacent loop; the loops of several rows are arranged correspondingly to form continuous loop stripes.

[0031] The loop yarns, formed during the weaving process, create the surface loops of the fabric, determining the fabric's surface texture, softness, and visual appearance. The base yarns, located at the bottom layer of the fabric, act as support yarns, carrying the surface loops and maintaining the overall dimensional stability and structural strength of the fabric. The terms "loop yarn" and "base yarn" are used to clearly distinguish their functions and do not imply differences or complete disparities in core parameters such as material, structure, quantity used, elasticity, shrinkage, or denier (D is an abbreviation for Denier, representing the thickness of a fiber or yarn). The naming itself does not imply limitations on the core parameters of the yarns; it is merely to clarify their functions and avoid confusion when describing fabric weaving. The specific configuration of the loop yarns and base yarns can be adjusted according to the target performance requirements of the fabric.

[0032] The loop yarn and base yarn can be made of composite yarns, monofilament yarns, or other structures to achieve diverse fabric effects. Ideally, both the loop yarn and base yarn should be composite yarns to enhance the visual depth and vintage texture of the faux denim fabric. Composite yarns are made by twisting together multiple monofilaments of different materials and fineness. The differences in their fiber structure create natural variations in color depth and texture undulations during the weaving process. When both the loop yarn and base yarn are composite yarns, they intertwine on the fabric surface to form a mottled texture. This texture effect closely matches the natural, aged look of traditional denim fabric after washing and bleaching, maximizing the restoration of the classic denim appearance.

[0033] The loop yarn and the base yarn can be made of yarns with the same or different shrinkage rates. Preferably, the base yarn has a greater shrinkage rate than the loop yarn. For example, if the loop yarn has a shrinkage rate of 5-7% and the base yarn has a shrinkage rate of 12-15%, after weaving into the fabric, the yarn shrinks during high-temperature setting. Because the base yarn shrinks much more than the loop yarn, the shrunken base yarn tightly wraps around and locks the loop structure formed by the loop yarn, significantly increasing the bonding strength between the loops and the loops. This effectively prevents problems such as loop unraveling and slippage, effectively improving the fabric's structural stability and tear resistance. Furthermore, the high shrinkage characteristics of the base yarn also increase the fabric's density, enhance its anti-pilling and abrasion resistance, and solve the problems of traditional imitation denim fabrics being prone to deformation and not durable.

[0034] The loop yarn and the base yarn can be made of yarns with the same or different denier (D) values. Preferably, the loop yarn has a higher D value than the base yarn; for example, the loop yarn is a 150D-200D composite yarn, and the base yarn is a 100D-150D composite yarn. A higher D value in the loop yarn results in a coarser fineness and a larger fiber cross-sectional area, ensuring the loops are full, thick, and durable. This allows the loop stripes arranged in corresponding rows to have a more prominent three-dimensional feel and visual depth, highlighting the appearance characteristics of the denim-like fabric. The base yarn, with a lower D value, completes the basic weave with a finer fineness, reducing the thickness and weight of the fabric's base layer, giving the fabric good softness, avoiding a heavy and stiff base layer, and improving the fabric's stiff wearing experience.

[0035] In each basic weave, the loop yarn forms a loop higher than the loop between at least one adjacent loop. The number of loops in each basic weave can be set based on the number of weave rows occupied by the basic weave. When the basic weave occupies a large number of weave rows, multiple loops can be set. Multiple loops can be set adjacently or spaced apart. For example, when weaving a seven-weave basic weave, two loops are formed; specifically, one loop is formed between the first and second weave rows, and one loop is formed between the fourth and fifth weave rows. When the basic weave occupies a small number of weave rows, the number of loops can be reduced accordingly. For example, when weaving a four-weave basic weave, one loop is formed, that is, the loop yarn forms a loop higher than the loop between an adjacent loop; this avoids excessive crowding of loops, which would lead to unclear patterns.

[0036] The aforementioned continuous terry stripes refer to loops formed by loop yarns in several weaves on the fabric, which correspond to each other in the spatial arrangement of the fabric (with gaps or continuous connections), forming raised textures with a linear, herringbone, or denim-like style at the visual level. Taking linear terry stripes as an example, their extension direction can be flexibly adjusted. They can be parallel to the weave direction to form vertical stripes that extend straight along the fabric, or they can be at a preset angle to the weave direction to form diagonal stripes.

[0037] Specifically, taking the example of four rows arranged in a cyclical pattern to form diagonal stripes, this application will be further explained. Loops are formed between the first and second weave columns in the basic structure of the first row; loops are formed between the second and third weave columns in the basic structure of the second row; loops are formed between the third and fourth weave columns in the basic structure of the third row; and loops are formed between the fourth weave column in the basic structure of the fourth row and the first weave column of the next basic structure.

[0038] The weaving process of the denim-like fabric described in this application can be achieved using specialized equipment such as terry machines and jacquard machines. The following explanation uses a terry machine as an example to further illustrate this application. The terry loop is formed when two adjacent loops are formed by a sinker pushing out the loop yarn between them, thus stretching the loop yarn. Specifically, the cylinder of the terry machine drives the knitting needles to hook the loop yarn and base yarn in a reciprocating motion to form loops. At the position where a terry loop needs to be formed, the knitting needles, carrying the hooked loop yarn and base yarn, rise to a predetermined height. Then, driven by a drive mechanism (such as a sinker ring or cam mechanism), the sinker pushes outward radially. The nose of the sinker presses against the bottom of the loop yarn loop, lifting it upwards. At this time, the knitting needles begin to descend, and the loop yarn is stretched due to the support of the sinker, thus forming a terry loop on the fabric surface that is higher than the base yarn loop. When the knitting needles descend to their lowest position, the base yarn and loop yarn form a fixed loop as the knitting needles descend.

[0039] The nose of the sinker, as a key component directly supporting the loop yarn, has a height that is positively correlated with the extent of loop protrusion: when the nose is higher, during the needle's ascent of the loop yarn, the nose can support the yarn to a higher position, resulting in a larger loop protrusion and ultimately increasing the loop height on the fabric surface; conversely, when the nose is lower, the support of the loop yarn is limited, and the loop height decreases accordingly. By adjusting the nose height, the protrusion of the loops can be flexibly controlled to suit the texture requirements of different denim-like fabrics. The preferred nose height of the sinker is set at 1.2-1.5mm. This parameter range ensures stable loop structure formation, preventing the loops from collapsing or snagging due to an excessively high nose, or failing to form a distinct denim texture due to an excessively low nose, while also placing the loop height within the optimal visual range, closely matching the texture of traditional denim fabrics.

[0040] By precisely controlling the yarn length corresponding to 100 needles, the loop yarn and base yarn can achieve stable shaping of the terry structure and optimization of the fabric texture. Specifically, the loop yarn length is set to 35-38cm within a 100-needle knitting cycle. This yarn length parameter provides sufficient yarn allowance for the sinker to push out the loops, ensuring that the loops can form a full, raised structure, while avoiding the problems of loose or flattened loops caused by excessively long yarns, effectively ensuring the three-dimensionality and stability of the loops. At the same time, the sufficient loop yarn length can work in conjunction with the pushing action of the sinker to create a uniform mottled texture on the fabric surface, enhancing the retro visual effect of the denim-like fabric. To match this, the base yarn is set to a length of 30-32cm within a 100-needle knitting cycle. This shorter yarn length compared to the loop yarn allows the base yarn to form tight, fixed loops, providing solid structural support for the fabric and ensuring a flat, non-deformable underside. Simultaneously, the difference in yarn length between the base and loop yarns creates a tension gradient, further fixing the height and shape of the loops and preventing defects such as loop shedding or deformation during subsequent processing or wear. This differentiated setting of loop and base yarn lengths, combined with the control logic of matching the nose height parameter of the sinker and the weave count to the number of loops, ensures that the faux denim fabric possesses both the classic texture of traditional denim and superior structural stability and wearing comfort.

[0041] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A weaving process for a terry cloth imitating denim fabric, characterized in that, The terry fabric, resembling denim, comprises several rows; each row includes at least loop yarn and base yarn, and is woven in a circular pattern based on several weave rows; in each basic weave, the loop yarn and base yarn together form loops, and the loop yarn forms loops higher than the loops at least between adjacent loops; the loops of several rows are arranged correspondingly to form continuous loop stripes.

2. The weaving process of the terry cloth imitation denim fabric according to claim 1, characterized in that, The terry stripes are either longitudinal stripes or diagonal stripes.

3. The weaving process of the terry cloth imitation denim fabric according to claim 1, characterized in that, The loop yarn forms a loop higher than the loop between a certain adjacent loop.

4. The weaving process of the terry cloth imitation denim fabric according to claim 1, characterized in that, Each row is a cyclical weave based on four weave columns.

5. The weaving process of the terry cloth imitation denim fabric according to claim 4, characterized in that, The terry-like denim fabric is composed of four rows arranged in a cycle; loops are formed between the first and second weaves in the basic structure of the first row; loops are formed between the second and third weaves in the basic structure of the second row; loops are formed between the third and fourth weaves in the basic structure of the third row; and loops are formed between the fourth weave in the basic structure of the fourth row and the first weave of the next basic structure.

6. The weaving process of the terry cloth imitation denim fabric according to claim 1, characterized in that, The shrinkage rate of the base yarn is 12-15%.

7. The weaving process of the terry cloth imitation denim fabric according to claim 5, characterized in that, The loop yarn is a 150D-200D composite yarn; the base yarn is a 100D-150D composite yarn.

8. The weaving process of the terry cloth imitation denim fabric according to claim 1, characterized in that, It is formed by weaving with a terry machine; the terry is formed when two adjacent loops are formed by pushing out the loop yarn between the two adjacent loops through a sinker, so that the loop yarn between the two adjacent loops is stretched.

9. The weaving process of the terry cloth imitation denim fabric according to claim 7, characterized in that, The nose height of the settling plate is 1.2-1.5mm.

10. The weaving process of the terry cloth imitation denim fabric according to claim 7, characterized in that, The length of the loop yarn with 100 needles is 35-38cm, and the length of the base yarn with 100 needles is 30-32cm.

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