Single-sided knitted fabric, its knitting system and preparation method

Abstract

The application discloses a single-sided knitted fabric, a knitting system and a preparation method thereof. Two yarns are fed to complete a complete knitting cycle, and one complete knitting cycle corresponds to one loop row of the fabric in the weft direction. The loop structure of the fabric is composed of normal loop units and pre-loop units. In the same loop row, the normal loop units and the pre-loop units are alternately arranged in the weft direction. The normal loop unit is a loop formed by normal loop shedding of the yarn and exposed on the front surface of the fabric. The pre-loop unit is a holding loop formed by holding of the yarn through a single knitting cycle and lengthening of the loop column and exposed on the back surface of the fabric. The pre-loop unit completes normal loop shedding in the next adjacent knitting cycle. The fabric is formed by alternating knitting of the normal loop unit and the pre-loop unit, and a single-sided knitted structure of the warp and weft is formed by transverse stringing and nesting loops and longitudinal constraint loop columns. The application can improve the problems of fabric rolling and scattering, improve the shape retention, and retain the soft and breathable characteristics.

Description

Technical Field

[0001] This invention relates to the field of knitted fabric weaving technology, and in particular to a single-sided knitted fabric, its weaving system, and its preparation method. Background Technology

[0002] Knitted weft-knitted plain weave fabric is the most basic and widely used fabric structure in the knitting industry, widely used in everyday clothing categories such as T-shirts, underwear, loungewear, and dresses. The surface of knitted weft-knitted plain weave fabric consists of a continuous loop structure. Due to the inherent characteristics of its loop structure, it has excellent elasticity, extensibility, breathability, and moisture absorption. Moreover, the single-sided structure of the fabric has smooth V-shaped loop columns on the front and rounded sinker arcs on the back, resulting in a soft and comfortable overall feel. It is a core basic fabric for mass-market clothing.

[0003] However, existing knitted weft-knitted plain weave fabrics have an inherent drawback: they cannot simultaneously achieve both softness and comfort and structural stability. Specifically: Severe fabric curling: Due to the internal stress of the coil structure, the edges of the fabric will naturally curl towards the front, which greatly hinders the cutting and sewing processes, significantly reduces production efficiency, and also affects the flatness of the garment. Poor structural stability: The coil structure of the fabric is easily stretched by external forces and undergoes permanent deformation. The fabric has weak shape retention and support. After repeated wear and washing, the garment is prone to loosening and deformation, resulting in a short service life. Insufficient durability: The coil structure on the fabric surface is prone to snagging and breakage, and after the coil breaks, it is easy to unravel along the longitudinal direction, and the damaged area will expand rapidly, further shortening the service life of the fabric. The problem of weft skew is prominent: the loop structure of conventional weft-knitted plain weave fabrics is prone to weft skew, which not only affects the uniformity of the fabric's appearance, but also reduces the fabric utilization rate of garment cutting and increases production costs.

[0004] For example, patent CN111501174A discloses a knitted fabric and its preparation method, which uses yarn containing low-melting-point chemical fibers and cotton yarn to be knitted alternately. High-temperature setting melts the low-melting-point fiber skin layer and causes multi-point adhesion, thereby offsetting the internal stress of the loops in the single-sided knitted fabric and improving the curling problem. However, the anti-curling effect of this solution is highly dependent on the finishing and setting process. After multiple washes, the adhesion points are prone to failure, and the anti-curling performance is severely degraded. At the same time, it is necessary to introduce multi-component yarns such as low-melting-point chemical fibers and elastic yarns, which not only increases the raw material cost, but also changes the original soft touch of pure cotton single-sided plain weave fabric, and cannot retain the core wearing advantages of conventional weft-knitted plain weave fabrics in terms of softness and breathability.

[0005] To address the aforementioned shortcomings, existing improvement solutions in the industry mainly fall into three categories: First, replacing single-sided plain weave with double-sided knitting structures, using the internal stress of the positive and negative loops to resolve the curling problem. However, this solution leads to a significant increase in fabric weight, reduced breathability, and a stiffer hand feel, completely negating the core advantages of single-sided plain weave fabrics—softness and lightness. Second, improving the curling and deformation problems of fabrics through finishing processes such as resin setting. However, this solution results in a worse hand feel, and the setting effect rapidly diminishes after multiple washes. Additionally, some setting auxiliaries pose environmental compliance risks. Third, improving fabric stability through complex jacquard and tuck weave structures. However, this solution involves complex knitting processes, extremely low production efficiency, and requires large-scale modifications to knitting equipment, resulting in high modification costs. It is also incompatible with the industry's commonly used weft knitting circular knitting machines, making it difficult to achieve large-scale mass production.

[0006] Therefore, how to solve the structural defects of existing fabrics in a low-cost and easily mass-producible manner while retaining the core advantages of softness, breathability and high elasticity of knitted weft plain weave fabrics has been a long-standing technical problem in this field. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a single-sided knitted fabric, its knitting system and preparation method, which can improve the problems of fabric curling and unraveling, improve shape retention, retain soft and breathable properties, reduce weft skew and improve the smoothness and fineness of the fabric surface.

[0008] To address the aforementioned technical problems, the first aspect of this invention discloses a single-sided knitted fabric with an integrated warp and weft structure. The fabric is constructed by feeding two yarns to complete a full knitting cycle, with each full knitting cycle corresponding to a loop row in the weft direction. The loop structure of the fabric consists of normal loop-forming units and pre-loop-forming units. Within the same loop row, the normal loop-forming units and pre-loop-forming units are arranged alternately along the weft direction. The normal loop-forming units are loops formed by the normal unwinding of yarn and are exposed on the front side of the fabric. The pre-loop-forming units are holding loops formed by the yarn being held and stretched through a single knitting cycle and are exposed on the reverse side of the fabric. The pre-loop-forming units complete normal unwinding in the next adjacent knitting cycle. Through the alternating knitting of normal loop-forming units and pre-loop-forming units, the fabric forms a single-sided knitted structure with an integrated warp and weft structure, consisting of transversely interlocking loops and longitudinally constrained loops.

[0009] As an optional implementation, in the first aspect of the invention, the normal looping unit and the pre-looping unit interchange positions in adjacent weaving cycles, so that the two yarns alternately complete looping and pre-looping on the front and back sides of the fabric.

[0010] The second aspect of this invention discloses a knitting system for knitting a single-sided knitted fabric with an integrated warp and weft structure as described in the first aspect of this invention. The knitting system includes a loop-forming system A and a loop-forming system B arranged alternately and cyclically along the circumference of the needle cylinder. Each loop-forming system includes two sinkers with different heel heights, two sinker triangles with different profiles, two needle triangles with different profiles, and two needles with different heel heights. The sinkers are a two-level heel structure, divided into high-heel sinkers and low-heel sinkers. The needles are divided into high-heel needles and low-heel needles.

[0011] As an optional implementation, in the second aspect of the present invention, the sinker triangle is divided into sinker triangle one and sinker triangle two. The track of sinker triangle one is a straight profile, which controls the sinker to cooperate with the knitting needle to complete the normal loop forming action. The track of sinker triangle two is an irregular wave profile, which controls the sinker to cooperate with the knitting needle to complete the pre-loop forming action.

[0012] As another optional implementation, in the second aspect of the present invention, the needle triangle is divided into a pre-looping triangle and a looping triangle. The looping triangle has a high-pointed mountain-shaped profile, which controls the needle to complete the normal loop-breaking and loop-forming action. The pre-looping triangle has a low-gradient mountain-shaped profile, which controls the needle to complete the pre-looping action of padding yarn without looping.

[0013] As another optional implementation, in the second aspect of the invention, in the loop-forming system A, the high-heel knitting needle cooperates with the loop-forming cam to complete normal loop-forming, and the low-heel knitting needle cooperates with the pre-loop-forming cam to complete pre-loop-forming; in the loop-forming system B, the high-heel knitting needle cooperates with the pre-loop-forming cam to complete pre-loop-forming, and the low-heel knitting needle cooperates with the loop-forming cam to complete normal loop-forming; the loop-forming system A and the loop-forming system B cooperate to allow the two yarns to alternately complete loop-forming and pre-loop-forming on the front and back sides of the fabric.

[0014] The third aspect of this invention discloses a method for preparing a single-sided knitted fabric with an integrated warp and weft structure as described in the first aspect of this invention, including a knitting process and a dyeing and finishing process; the knitting process adopts the knitting system described in the second aspect of this invention, and completes the normal loop formation and pre-loop formation of double yarns through the alternating cycle of loop forming system A and loop forming system B to obtain the fabric greige; the dyeing and finishing process includes, in sequence, sizing and bleaching, singeing, dyeing and softening agent treatment, washing and drying of wool particles, and setting treatment.

[0015] As an optional implementation, in a third aspect of the invention, the singeing process is used to remove loose fibers and fuzz from the surface of the fabric.

[0016] As another optional implementation, in the third aspect of the present invention, the flat-width scouring and bleaching is completed using a flat-width scouring and bleaching machine, the singeing is completed using a singeing machine, the dyeing and softening agent treatment is completed in a dyeing vat, the wool washing is completed using a wool washing machine, and the setting treatment is completed using a setting machine.

[0017] Compared with the prior art, the embodiments of the present invention have the following beneficial effects: Compared to existing technologies, this invention, through the alternating weaving of normal loop units and pre-loop units, forms a warp-weft integrated constraint structure, which counteracts the curling internal stress of conventional single-sided plain weave loops, significantly improving the problem of fabric curling edges. It also reduces the risk of longitudinal loop unraveling, solving the technical defects of conventional plain weave fabrics, such as difficulty in cutting and sewing and easy continuous unraveling after damage. The elongated loop column structure of the pre-loop units forms a continuous weft constraint skeleton, reducing the fabric's external force stretching deformation rate and improving its support and shape retention. This solves the technical defects of conventional plain weave fabrics, such as easy stretching and loosening, and deformation after multiple wear and washing. The overall structure is a single-sided knitted structure, without introducing double-sided structures, high-modulus stiff yarns, or resin setting processes. It fully retains the core advantages of conventional weft-knitted plain weave fabrics—softness, comfort, breathability, and moisture absorption—avoiding the problems of stiffening of the hand feel, decreased breathability, and reduced performance after washing caused by existing improvement schemes. The alternating weaving structure of the two yarns results in smaller loop gaps and a smoother, finer fabric surface, significantly reducing the fabric's weft skew and improving the fabric's appearance consistency and garment cutting utilization rate. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a single-sided knitted fabric with an integrated warp and weft structure disclosed in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a high-heeled sinking plate disclosed in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a low-heel sinking plate disclosed in an embodiment of the present invention; Figure 4 This is a schematic diagram of a triangular settling plate structure disclosed in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of a knitting needle triangle disclosed in an embodiment of the present invention; Figure 6 This is a schematic flowchart of a method for preparing a single-sided knitted fabric disclosed in an embodiment of the present invention. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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.

[0021] Example 1 See Figures 1-5 This invention discloses a single-sided knitted fabric 1 with an integrated warp and weft structure. The fabric is made by feeding two yarns to complete a complete knitting cycle, and a complete knitting cycle corresponds to a loop row in the weft direction of the fabric. The loop structure of the fabric consists of normal loop forming units 11 and pre-loop forming units 12. In the same loop row, the normal loop forming units 11 and pre-loop forming units 12 are arranged alternately along the weft direction. The normal loop forming unit 11 is a loop formed by the normal unwinding of the yarn and is exposed on the front side of the fabric. The pre-loop forming unit 12 is a holding loop formed by the yarn being held and the loop post being stretched through a single knitting cycle and is exposed on the reverse side of the fabric. The pre-loop forming unit 12 completes normal unwinding in the next adjacent knitting cycle. The fabric forms a single-sided knitted structure with an integrated warp and weft structure composed of transverse interlocking loops and longitudinal constraint loop posts through the alternating knitting of normal loop forming units 11 and pre-loop forming units 12.

[0022] This invention, through the alternating weaving of normal loop-forming units 11 and pre-loop-forming units 12, forms a warp-weft integrated constraint structure, which counteracts the curling internal stress of conventional single-sided plain weave loops, significantly improving the problem of fabric curling edges. It also reduces the risk of longitudinal loop unraveling, solving the technical defects of conventional plain weave fabrics, such as difficulty in cutting and sewing and easy continuous unraveling after damage. The elongated loop column structure of the pre-loop-forming units 12 forms a continuous weft constraint skeleton, reducing the fabric's external force stretching deformation rate and improving its support and shape retention. This solves the technical defects of conventional plain weave fabrics, such as easy stretching and loosening, and deformation after multiple wear and washing. The overall structure is a single-sided knitted structure, without introducing double-sided structures, high-modulus stiff yarns, or resin setting processes. It fully retains the core advantages of conventional weft-knitted plain weave fabrics—softness, comfort, breathability, and moisture absorption—avoiding the problems of stiffening of the hand feel, decreased breathability, and reduced performance after washing caused by existing improvement schemes. The alternating weaving structure of the two yarns results in smaller loop gaps and a smoother, finer fabric surface, significantly reducing the fabric's weft skew and improving the fabric's appearance consistency and garment cutting utilization rate.

[0023] In an optional embodiment, the normal looping unit 11 and the pre-looping unit 12 interchange positions in adjacent weaving cycles, so that the two yarns alternately complete looping and pre-looping on the front and back of the fabric.

[0024] In this embodiment, two yarns alternately form loops and pre-form loops on both sides of the fabric, resulting in a more balanced distribution of stress within the loops on both sides of the fabric. This further reduces the probability of fabric curling and weft skew, and improves the long-term stability of the fabric structure. The alternating formation of standard loops on the front side of the fabric by the two yarns avoids the uneven fabric texture and evenness caused by continuous looping of a single yarn, further improving the smoothness and fineness of the fabric surface and optimizing the appearance quality of the fabric. The interchange of looping and pre-forming loops in adjacent weaving cycles allows the elongated loop posts of the pre-forming loop unit 12 to form a continuous longitudinal constraint structure, creating a stable warp and weft interlacing effect with the transverse loop rows, further reducing the fabric's stretch deformation rate and improving its shape retention.

[0025] Optionally, in adjacent weaving cycles, within the loop row woven by loop system A, the first yarn forms a normal loop unit 11 on the front side of the fabric, and the second yarn forms a pre-loop unit 12 on the bottom side of the fabric; within the next adjacent loop row woven by loop system B, the first yarn forms a pre-loop unit 12 on the bottom side of the fabric, and the second yarn forms a normal loop unit 11 on the front side of the fabric, and the cycle repeats.

[0026] Example 2 See Figures 2-5 This invention discloses a knitting system for knitting a single-sided knitted fabric 1 with an integrated warp and weft structure as described in Embodiment 1. The knitting system includes a loop-forming system A and a loop-forming system B arranged alternately around the circumference of the needle cylinder. Each loop-forming system includes two sinkers with different heel heights, two sinker triangles with different profiles, two needle triangles with different profiles, and two needles with different heel heights. The sinkers are a two-level heel structure, divided into a high-heel sinker 2 and a low-heel sinker 3. The needles are divided into high-heel needles and low-heel needles.

[0027] This invention, through its modular design featuring double-heel needles, double-stage heel sinkers, and double-contour triangles, allows for direct modification and installation on existing general-purpose single-sided weft knitting circular knitting machines without requiring replacement of the entire machine. This enables continuous knitting of the warp and weft integrated single-sided knitted fabric 1 described in this application, significantly reducing equipment modification costs and fully adapting to the industry's large-scale mass production needs. The independent coordination of needles, sinkers, and corresponding triangles at different heel positions allows for separate control of normal loop-forming and pre-loop-forming knitting actions, avoiding mutual interference between the two actions, ensuring the stability of loop-forming and pre-loop-forming effects, and improving the yield rate of the knitted fabric. The alternating loop-forming system A and loop-forming system B allow for flexible adjustment of the alternation frequency of loop-forming and pre-loop-forming, adapting to the knitting needs of fabrics with different yarn specifications and weights, thus expanding the applicability of the equipment.

[0028] In the attached diagram, the heel of the high-heel sinking plate 2 is 21, and the heel of the low-heel sinking plate 3 is 31.

[0029] In an optional embodiment, the sinker triangle is divided into sinker triangle one 4 and sinker triangle two 5. The track 41 of sinker triangle one 4 has a straight profile, which controls the sinker to cooperate with the knitting needle to complete the normal loop forming action. The track 51 of sinker triangle two 5 has an irregular wavy profile, which controls the sinker to cooperate with the knitting needle to complete the pre-loop forming action.

[0030] This embodiment uses two sinker triangles with different contours to independently control the sinker pressing action for normal looping and pre-looping, ensuring precise loop support and positioning of the sinker during normal looping, and stable pressing and holding action of the sinker during pre-looping, avoiding yarn slippage and loop deformation. The contour of sinker triangle 25 is adapted to the action requirements of pre-looping, and can accurately control the forward and backward movement of the sinker. It works in conjunction with the pre-looping action of the knitting needle to stably hold the yarn, ensuring consistent loop length of the pre-looping unit 12 and improving fabric uniformity. The two sinker triangles are modularly designed and can directly replace the sinker triangles of existing general single-face knitting machines without large-scale modification of the needle cylinder and sinker ring, resulting in low modification cost and convenient installation and debugging.

[0031] In another optional embodiment, the knitting needle triangle is divided into a pre-looping triangle 7 and a looping triangle 6. The needle track 61 of the looping triangle 6 has a high-pointed mountain-shaped profile, which controls the knitting needle to complete the normal loop-breaking and loop-forming action. The needle track 71 of the pre-looping triangle 7 has a low-gradient mountain-shaped profile, which controls the knitting needle to complete the pre-looping action of padding yarn without looping.

[0032] This embodiment uses two different knitting needle triangles to independently control the normal loop-forming and pre-loop-forming motion trajectories of the knitting needle. This ensures that the loop-forming triangle 6 can drive the knitting needle to complete the full loop-forming action, while the pre-loop-forming triangle 7 can drive the knitting needle to complete the pre-loop-forming action without slipping the yarn. The two actions do not interfere with each other, resulting in high knitting precision. The contours of the loop-forming triangle 6 and the pre-loop-forming triangle 7 correspond to the knitting requirements of the normal loop and pre-loop structure, respectively, allowing for precise control of the knitting needle's lifting and lowering stroke. This ensures consistent loop size during normal loop-forming and stable loop length during pre-loop-forming, improving the fabric's weight uniformity and surface consistency. The two knitting needle triangles are independently modular and can be replaced and adjusted individually, facilitating adjustments to the knitting needle stroke according to different yarn specifications and fabric weights, adapting to different knitting process requirements.

[0033] In another optional embodiment, in the loop-forming system A, the high-heel needle cooperates with the loop-forming triangle 6 to complete normal loop-forming, and the low-heel needle cooperates with the pre-loop-forming triangle 7 to complete pre-loop-forming; in the loop-forming system B, the high-heel needle cooperates with the pre-loop-forming triangle 7 to complete pre-loop-forming, and the low-heel needle cooperates with the loop-forming triangle 6 to complete normal loop-forming; the loop-forming system A and the loop-forming system B cooperate to allow the two yarns to alternately complete loop-forming and pre-loop-forming on the front and back sides of the fabric.

[0034] This embodiment utilizes the differentiated coordination between the high-heel and low-heel needles and their corresponding triangles in loop-forming systems A and B. This allows the equipment to automatically complete the alternating loop-forming and pre-forming actions of adjacent loop rows during continuous operation, eliminating the need for manual intervention and achieving continuous mass production of the fabric. The production efficiency is consistent with that of conventional single-sided plain weave fabrics. The one-to-one coordination logic of loop-forming systems A and B ensures synchronized movements of the high-heel and low-heel needles, and coordinated movements of normal loop-forming and pre-forming, avoiding faults such as needle collisions, yarn jams, and yarn breaks. This improves the stability of high-speed equipment operation and reduces the fabric defect rate. Through fixed coordination logic, the loop-forming and pre-forming actions of each knitting cycle are completely consistent, resulting in a uniform loop structure, significantly reduced weft skew, and greatly improved fabric smoothness.

[0035] Optionally, the design of the knitting parts in this invention can be based on standard parts of industry-standard single-sided weft knitting circular knitting machines. The core design principle is to ensure that the high and low heel parts move independently without interference, accurately achieving alternating knitting actions of normal loop formation and pre-loop formation. The specific determination method can be as follows: 1. Determining the heel dimensions of high / low heel needles and double-stage heel sinkers. Step 1: First, select a single-sided weft knitting circular knitting machine model commonly used in the knitting industry (such as a 30-inch 28-needle / 32-needle model for regular T-shirt fabrics, or a 34-needle model for high-density underwear fabrics), and obtain the basic installation dimensions of the original factory standard needles and sinkers; Step 2: Using the original factory standard heel height as a reference, raise the high heel part above the reference height, and adjust the low heel part up or down from the reference height. The height difference between the high and low heels should be within the industry-standard safe range. Step 3: Qualification verification standard: When the machine is running idle, the high-heel parts are only controlled by the corresponding high-track triangle, and the low-heel parts are only controlled by the corresponding low-track triangle, with no cross-movement, no impact pins, and no motion interference.

[0036] 2. Determining the outline and stroke of the knitting needle triangle (knitting loop triangle / pre-knitting loop triangle) Looping triangle (for normal looping): Based on the original standard plain weave looping triangle of the compatible model, the needle track adopts the industry-standard high-pointed mountain shape profile, and the maximum needle lift meets the requirements for normal looping and looping; Qualification verification standard: After the needle completes the action, a complete loop is formed, with no missing needles or broken yarns.

[0037] Pre-forming triangle (for padding without forming loops): The needle track adopts a low and gentle mountain-shaped profile. The core design principle is that the maximum lift is less than the lift of the forming triangle. The lift difference is based on the principle that "the old loop does not fall off after the needle padding and the yarn is stably held in the needle hook". Qualification verification standard: After a single knitting, the yarn does not fall off the loop, and the yarn held in the needle hook can normally fall off and form loops in the next knitting system without unraveling or yarn jamming.

[0038] 3. Determining the outline of the settlement plate triangle Settling plate triangle 1 (for normal loop formation): It adopts a flat contour track that is compatible with the original factory standard of the machine model, controls the settling plate to complete the normal loop support and clearance action, and works with the knitting needle to complete the normal loop formation.

[0039] Settling plate triangle 2 (for pre-loop formation): It adopts an irregular wave contour track to control the settling plate to push forward and press down the old loop during the pre-loop formation stage, and cooperate with the knitting needle to complete the yarn padding and loop-free action; Qualification verification standard: During the pre-loop formation action, the old loop does not rise with the knitting needle, there is no needle flipping, and no accidental loop-free.

[0040] Example 3 See Figure 6 This invention discloses a method for preparing a single-sided knitted fabric 1 with an integrated warp and weft structure as described in Embodiment 1, including a knitting process and a dyeing and finishing process. The knitting process employs the knitting system described in Embodiment 2, using alternating cycles of loop-forming system A and loop-forming system B to complete the alternating normal loop-forming and pre-loop-forming knitting of the double yarns, thus obtaining the fabric greige. The dyeing and finishing process sequentially includes sizing and bleaching, singeing, dyeing and softening agent treatment, scouring and drying of the wool particles, and setting treatment.

[0041] This invention, through its complementary weaving and dyeing processes, stably preserves the integrated warp and weft loop structure of the fabric, preventing structural damage during dyeing and finishing. This ensures stable anti-curling, anti-deformation, and anti-fraying properties of the finished fabric. Singeing removes surface fuzz, and combined with softening agents and setting treatments, the fabric surface becomes smooth and delicate, with a soft and comfortable feel. It also enhances the fabric's instantaneous cooling and anti-permeability properties, optimizing the wearing experience. The dyeing and finishing process utilizes standard equipment and mature processes commonly used in the knitting industry, directly adaptable to existing dyeing plant production lines without requiring additional specialized equipment. Process parameters are controllable, resulting in high consistency and stable yield rates for fabrics produced on a large scale. Through flat-width sizing, bleaching, and setting treatments, the fabric's skewness and washing shrinkage are further reduced, improving dimensional stability and resolving the technical defects of conventional plain weave fabrics that are prone to shrinkage and increased skewness after dyeing and finishing.

[0042] In an optional embodiment, the singeing process is used to remove loose fibers and fuzz from the surface of the fabric.

[0043] In another optional embodiment, the flat-width scouring and bleaching is performed using a flat-width scouring and bleaching machine, the singeing is performed using a singeing machine, the dyeing and softening agent treatment is performed in a dyeing vat, the wool washing is performed using a wool washing machine, and the setting treatment is performed using a setting machine.

[0044] Each process utilizes standard equipment specific to the knitting industry, enabling precise control of process parameters and ensuring stable results in flat-width scouring, singeing, dyeing, wool washing, and setting. This results in high consistency in fabric quality across batch production. The use of a flat-width scouring machine avoids the problems of coil stretching and deformation, and increased weft skew caused by rope-like scouring, better preserving the integrated warp and weft structure of the fabric. A setting machine further optimizes the fabric's dimensional stability and reduces washing shrinkage. A dedicated wool washing machine removes lint and pilling from the fabric surface, preventing pilling after wear and improving the fabric's long-term durability. All equipment used in each process is standardized and universally applicable in the knitting and dyeing industry, eliminating the need for additional dedicated production lines and allowing direct integration with existing dyeing and finishing capacity to meet the demands of large-scale fabric production.

[0045] The weaving process of this invention can be based on the mature process of conventional weft-knitted plain weave fabrics of the same machine size, and can be determined through routine trial weaving and adjustments. The specific method is as follows: The knitting machine size and cylinder diameter are selected based on the weight and intended use of the target fabric (e.g., 28-gauge / 32-gauge corresponds to regular T-shirts and loungewear fabrics, while 34-gauge / 36-gauge corresponds to high-density underwear fabrics). The yarn used is standard short-fiber / filament yarn from the knitting industry, with the yarn count matching the selected machine size (e.g., a 28-gauge machine corresponds to 40S~60S pure cotton yarn). The yarn feeding tension, loop length, and knitting speed are all based on the process parameters of a standard plain weave fabric of the same machine size, and fine-tuned through small-batch trial knitting. The acceptance criteria are: a smooth fabric surface without horizontal stripes, uniform loop structure between pre-formed and normal-formed loops, and fabric weight deviation controlled within ±5%.

[0046] The dyeing and finishing process of this invention is based on the mature dyeing and finishing process of conventional single-sided plain weave fabrics in the knitting industry. The core adjustment principle is to avoid damaging the pre-loop constraint structure of the fabric. The method for determining the parameters of each process is as follows: Flat-width bleaching: A flat-width bleaching machine is used, with process parameters based on the conventional bleaching parameters of the same material fabric. The operating tension is lower than that of conventional plain weave fabric to avoid the coils being stretched and deformed.

[0047] Singeing: The standard singeing process for knitted fabrics is adopted. The machine speed and flame temperature are set to ensure that "the fabric is clean of lint and hair without damaging the fabric coil structure" as the qualified standard.

[0048] Dyeing and softening treatment: The same dyeing process as the fabric is used. The softening agent is a general-purpose hydrophilic softener for knitted fabrics, and the amount is slightly adjusted according to the desired hand feel of the fabric.

[0049] Setting: A tenter frame is used. The setting temperature, overfeed, and speed are set according to the standard of "stable fabric dimensions, weft skew ≤1%, and washing shrinkage ≤±3%". Adjustments are made through routine trial setting.

[0050] The following are experimental tests conducted on the finished fabric: 1. Using the Phabrometer 3 smart fabric style meter, the drape, toughness, and smoothness of the fabric were evaluated. Under constant temperature conditions of 65% relative humidity and 21 degrees Celsius, the fabric was conditioned for 4 hours. Five pieces of fabric were then taken and a weight of 4 pounds was applied for measurement. The data are as follows:

[0051] As can be seen from the table, the drape, toughness, and smoothness of a single-sided knitted fabric with an integrated warp and weft structure are all superior to those of ordinary knitted weft-knitted plain weave.

[0052] 2. The cooling sensation coefficient of the fabric was evaluated according to GB / T35263-2017 "Test and Evaluation of Cooling Properties of Textiles Upon Contact". Sample stage material: polystyrene foam; instrument model: RoachesQMax; hot plate temperature: 35.0℃; cold plate temperature: 20.0℃. The test result shows a Q-MAX value of 0.23, proving that the fabric has excellent cooling properties, superior to conventional plain weave.

[0053] The content disclosed in the embodiments of this invention is only a preferred embodiment of the invention and is used only to illustrate the technical solutions of the invention, not to limit it. Although the invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this invention.

Claims

1. A single-sided knitted fabric with an integrated warp and weft structure, characterized in that, The fabric is knitted by feeding two yarns to complete one complete knitting cycle, and one complete knitting cycle corresponds to a loop row in the weft direction of the fabric. The loop structure of the fabric consists of normal loop-forming units and pre-loop-forming units. In the same loop row, the normal loop-forming units and pre-loop-forming units are arranged alternately along the weft direction. The normal loop-forming units are loops formed by the normal unwinding of the yarn and are exposed on the front side of the fabric. The pre-loop-forming units are holding loops formed by the yarn being held and the loop post being stretched through a single knitting cycle and are exposed on the reverse side of the fabric. The pre-loop-forming units complete normal unwinding in the next adjacent knitting cycle. Through the alternating knitting of normal loop-forming units and pre-loop-forming units, the fabric forms a warp-weft integrated single-sided knitted structure composed of transverse interlocking loops and longitudinal constraint loop posts.

2. The single-sided knitted fabric with an integrated warp and weft structure according to claim 1, characterized in that, The normal looping unit and the pre-looping unit exchange positions in adjacent weaving cycles, so that the two yarns alternately complete looping and pre-looping on the front and back of the fabric.

3. A weaving system for weaving a single-sided knitted fabric with an integrated warp and weft structure as described in claim 1 or 2, characterized in that, The knitting system includes a looping system A and a looping system B arranged alternately around the circumference of the needle cylinder. Each looping system includes two sinkers with different heel heights, two sinker triangles with different profiles, two needle triangles with different profiles, and two needles with different heel heights. The sinkers are a two-level heel structure, divided into high-heel sinkers and low-heel sinkers. The needles are divided into high-heel needles and low-heel needles.

4. The weaving system according to claim 3, characterized in that, The settling plate triangle is divided into settling plate triangle one and settling plate triangle two. The track of settling plate triangle one is a straight contour, which controls the settling plate to cooperate with the knitting needle to complete the normal loop forming action. The track of settling plate triangle two is an irregular wavy contour, which controls the settling plate to cooperate with the knitting needle to complete the pre-loop forming action.

5. The weaving system according to claim 3, characterized in that, The knitting needle triangles are divided into pre-looping triangles and looping triangles. The looping triangle has a high, pointed mountain-shaped needle track to control the knitting needle to complete the normal loop-breaking and loop-forming action. The pre-looping triangle has a low, gentle mountain-shaped needle track to control the knitting needle to complete the pre-looping action of padding yarn without forming loops.

6. The weaving system according to claim 3, characterized in that, In the loop-forming system A, the high-heel needle and the loop-forming cam work together to complete normal loop-forming, and the low-heel needle and the pre-loop-forming cam work together to complete pre-loop-forming; in the loop-forming system B, the high-heel needle and the pre-loop-forming cam work together to complete pre-loop-forming, and the low-heel needle and the loop-forming cam work together to complete normal loop-forming; the loop-forming system A and the loop-forming system B work together to allow the two yarns to alternately complete loop-forming and pre-loop-forming on the front and back sides of the fabric.

7. A method for preparing a single-sided knitted fabric with an integrated warp and weft structure as described in claim 1 or 2, characterized in that, It includes a weaving process and a dyeing and finishing process; the weaving process adopts the weaving system described in any one of claims 4-6, and completes the normal looping and pre-looping alternating weaving of double yarns through the alternating cycle of looping system A and looping system B to obtain the fabric greige; the dyeing and finishing process includes, in sequence, scalding and bleaching, singeing, dyeing and softening agent treatment, washing and drying of wool particles, and setting treatment.

8. The preparation method according to claim 7, characterized in that, The singeing process is used to remove loose fibers and fuzz from the surface of the fabric.

9. The preparation method according to claim 7, characterized in that, The flat-width scalding and bleaching is completed using a flat-width scalding and bleaching machine; the singeing is completed using a singeing machine; the dyeing and softening agent treatment is completed in a dyeing vat; the wool washing and granulation is completed using a wool washing and granulation machine; and the setting treatment is completed using a setting machine.

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