Warp-knitted fabric and method for producing the same

Abstract

The present application relates to the technical field of warp knitted fabric, and discloses a warp knitted fabric and a preparation method thereof. The warp knitted fabric is knitted by at least two kinds of yarns, i.e. a first yarn and a second yarn. The first yarn is octagonal star-shaped hollow polyester fiber, and the second yarn is polyester low-elasticity filament. The mass ratio of the first yarn to the second yarn is 50-58:42-50. The cross section of the single yarn body of the octagonal star-shaped hollow polyester fiber is square ring-shaped, and eight wings are arranged on the outer wall in the circumferential direction. The eight wings are evenly distributed on the four outer walls of the square ring, and the lengths of the wings on the circumferentially adjacent outer walls are not equal. The octagonal star-shaped hollow polyester fiber is used as the material, so that the hollow degree of the fabric can be maintained, and better air permeability can be achieved.

Description

Technical Field

[0001] This invention relates to the field of warp-knitted fabric technology, specifically to a warp-knitted fabric and its preparation method. Background Technology

[0002] Warp-knitted jacquard fabrics are widely used in sportswear, casual wear, and home textiles due to their rich pattern expressiveness and production efficiency. Traditional jacquard fabrics are mostly woven from a single polyester or nylon raw material. Although they have good shape retention and high strength, they lack moisture absorption and perspiration wicking properties and a soft, skin-friendly feel (i.e., "cotton feel"), making it difficult to meet consumers' growing demand for high-end functional textiles.

[0003] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of the present invention, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0004] To provide a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. This summary is not intended as a general commentary, nor is it intended to identify key / important components or describe the scope of these embodiments, but rather as a prelude to the detailed description that follows.

[0005] This invention addresses the limitations of existing technologies by providing a more comprehensive solution: a warp-knitted fabric and its preparation method. This solution overcomes the performance shortcomings of existing jacquard fabrics, including poor moisture absorption and wicking properties, and a lack of softness and skin-friendly feel. The solution to these problems is achieved through a complex combination of techniques, including improvements to the preparation method of the warp-knitted fabric.

[0006] In some embodiments, a warp-knitted fabric is woven from at least two types of yarns: a first yarn and a second yarn, wherein the first yarn is made of octagonal star-shaped hollow polyester fiber filaments and the second yarn is made of low-elastic polyester filaments; the mass ratio of the first yarn to the second yarn is 50-58:42-50; The monofilament of the octagonal star-shaped hollow polyester fiber has a square ring-shaped cross-section and eight wings on the outer circumferential surface. The eight wing bodies are distributed on the four outer walls of the square ring, and the lengths of the wing bodies on adjacent circumferential outer walls are not equal.

[0007] In some embodiments, the wing body is elongated, with one end connected to the outer wall and the other end extending away from the outer wall.

[0008] In some embodiments, the other ends of the two wings on the same outer wall are arranged to be opposite each other and far apart.

[0009] In some embodiments, the square ring is rectangular, and the length of the wing body on the long side is greater than the length of the wing body on the short side.

[0010] In some embodiments, a method for preparing a warp-knitted fabric as described above includes preparing octagonal star-shaped hollow polyester fiber filaments, which are obtained by using polyethylene terephthalate through a solution spinning process via a spinneret. The spinneret includes a square ring hole and eight slots. The eight slots are evenly distributed on the outer periphery of the square ring hole, and one end of each slot is connected to the four outer sides of the square ring hole. The extension lengths of the slots on adjacent sides of the square ring hole are not equal.

[0011] In some embodiments, the first yarn is obtained by physically modifying the octagonal star-shaped hollow polyester fiber filaments: The physical modification treatment includes twisting and feathering the octagonal star-shaped hollow polyester fiber filaments using a ring spinning machine. The ring spinning machine includes a front rubber roller, a spindle, a yarn tube, a grinding roller, and a ring rail. The grinding roller and the spindle are axially parallel on the ring rail, and the yarn tube is sleeved on the spindle. The octagonal star-shaped hollow polyester fiber filaments sequentially contact the front rubber roller and the grinding roller, and finally wind onto the yarn tube. Both the front rubber roller and the grinding roller rub the outer surface of the octagonal star-shaped hollow polyester fiber filaments, causing fuzz to form on the outer surface of the octagonal star-shaped hollow polyester fiber filaments, thus forming the first yarn. In some embodiments, the surface roughness of the front rubber roller is set to 1.5~12 and the hardness is 70~85 degrees; and / or, the abrasive grain size on the abrasive roller is set to 500~700 mesh.

[0012] In some embodiments, the method further includes weaving the first yarn: the first yarn is woven by two Jacquard combs using a complementary open-thread method, wherein one Jacquard comb is used for a yarn-threading cycle of threading one multifilament and skipping one needle position, and the other Jacquard comb is used for a yarn-threading cycle of skipping one needle position and threading one multifilament.

[0013] In some embodiments, the method further includes weaving the second yarn: the polyester low-elasticity yarn is woven by a full-thread method, wherein the full-thread method includes a yarn-threading cycle in which one polyester low-elasticity yarn is threaded through each needle.

[0014] In some embodiments, the polyester low-elasticity yarn is composed of two types of monofilaments with wavy and flat cross sections and circular cross sections, wherein the ratio of the two types of monofilaments with wavy and flat cross sections to circular cross sections is set to 55%~70%:30%~45%.

[0015] The warp-knitted fabric and its preparation method provided in this invention can achieve the following technical effects: The warp-knitted fabric uses octagonal star-shaped hollow polyester fibers. The cross-section of these fibers features square rings with wings of varying lengths on the outer periphery, creating grooves of different depths on the fiber surface. This forms capillary channels, improving breathability and giving the warp-knitted fabric excellent breathability. Combined with low-elastic polyester yarn, the entire fabric is lightweight, warm, fluffy, soft, moisture-wicking, quick-drying, heat-blocking, breathable, and slightly elastic, offering high comfort and combining the excellent properties of cotton and polyester.

[0016] The above general description and the description below are exemplary and explanatory only, and are not intended to limit the invention. Attached Figure Description

[0017] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements. The drawings are not to be scaled. And wherein: Figure 1 This is a schematic diagram of the spinneret structure provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the monofilament cross-section structure of the octagonal star-shaped hollow polyester fiber provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the principle structure of a ring spinning machine provided in an embodiment of the present invention.

[0018] Figure label: 1. Spinneret; 11. Spinneret orifice; 2. Monofilament; 20. Hollow section; 21. Long side; 211. First wing body; 212. Second wing body; 22. Short side; 221. Third wing body; 222. Fourth wing body; 3. Ring spinning frame; 30. Multifilament body; 31. Cylindrical bobbin; 32. Guide roller; 33. Guide wheel; 34. Front roller; 35. Front roller; 36. Guide hook; 37. Ring rail; 38. Yarn tube; 39. Frosting roller; 40. Imitation cotton octagonal star hollow polyester filament yarn. Detailed Implementation

[0019] To provide a more detailed understanding of the features and technical content of the embodiments of the present invention, the implementation of the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of the present invention. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be shown in a simplified manner to simplify the drawings.

[0020] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of the invention described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0021] In this embodiment of the invention, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better describing the embodiments of the invention and their implementations, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to require them to be constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of the invention according to the specific circumstances.

[0022] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this invention according to the specific circumstances.

[0023] Unless otherwise stated, the term "multiple" means two or more.

[0024] In this embodiment of the invention, the character " / " indicates that the objects before and after it are in an "or" relationship. For example, A / B means: A or B.

[0025] The term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0026] It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other.

[0027] This invention provides a warp-knitted fabric, comprising at least two types of yarns: a first yarn and a second yarn. The first yarn is made of octagonal star-shaped hollow polyester fiber, and the second yarn is made of low-elastic polyester yarn. The mass ratio of the first yarn to the second yarn is 50-58:42-50. The monofilament 2 of the octagonal star-shaped hollow polyester fiber has a square ring-shaped cross-section and eight wings on the outer circumferential surface. The eight wing bodies are distributed on the four outer walls of the square ring, and the lengths of the wing bodies on adjacent circumferential outer walls are not equal.

[0028] The warp-knitted fabric of this invention is woven from two different yarns. The first yarn is made of octagonal star-shaped hollow polyester fiber, which increases the fabric's breathability by utilizing its structural characteristics. Combined with low-elastic polyester yarn, the entire fabric is lightweight, warm, fluffy, soft, moisture-wicking, quick-drying, heat-blocking, breathable, and slightly elastic, offering superior comfort and combining the excellent properties of both cotton and polyester.

[0029] In practical use, other auxiliary yarns can be added, including yarns that improve the overall color and pattern.

[0030] The octagonal star-shaped hollow polyester fiber has a square ring cross-section structure, with eight wings of different lengths set on the outer wall of the square ring. More specifically, the eight wings are evenly distributed on the four outer walls, that is, each outer wall has two wings; the eight wings form an octagonal star structure.

[0031] The aforementioned square ring shape is produced by spinning, so the fiber material structure is not fixed. The square ring shape is usually similar to a square, but not a square ring in the strict sense. The four sides and eight wings of the square ring may be curved.

[0032] Because the lengths of the wings on the outer wall of the monofilament 2 are different, grooves of varying depths extending along the length of the monofilament 2 are formed on its outer periphery, constituting capillary channels. These channels can quickly absorb liquid sweat and moisture from the skin surface and diffuse and conduct it outward along the grooves to the fabric surface, accelerating evaporation and ensuring the skin remains dry and comfortable. In the multifilament 30 structure composed of multiple monofilaments 2, the distance between adjacent monofilaments 2 is relatively increased due to the difference in wing lengths, forming irregular small grooves that increase the breathability of the fabric.

[0033] The embodiments of the present invention provide, as follows Figure 2The octagonal star-shaped hollow polyester fiber monofilament 2 shown in the cross section includes a square ring-shaped main body with a hollow part 20, which allows the entire monofilament 2 to store air, improving its warmth and heat insulation properties, and is lightweight. In this invention, the main body is square ring-shaped, including square ring-like structures with straight outer walls and curved or arc-shaped outer walls, all of which can store air to improve the warmth of the monofilament 2.

[0034] Because the square ring-shaped main body has a hollow section 20 in the middle, the hollow ratio (the ratio of the area occupied by the hollow cavity in the cross section) is greater than that of traditional hollow fiber. This allows for lower precision and reduced costs in mold making, while ensuring hollow ratio, light weight and thermal insulation.

[0035] Optionally, the wing body is elongated, with one end connected to the outer wall and the other end extending away from the outer wall.

[0036] The wing body of this embodiment adopts a long strip structure, with one end connected to the outer wall of the square ring-shaped main body and the other end extending away from the outer wall. By setting the long strip wing body on the outer wall, the outer surface area of ​​the entire monofilament 2 is increased. Even in the multifilament structure, the long strip structure makes the adjacent monofilaments 2 set with a large spacing, thereby increasing the fluffiness and breathability.

[0037] The eight corresponding wing bodies are evenly distributed on the outer wall of the square ring-shaped main body, which reflect and scatter light from multiple angles. This can reflect sunlight back, reduce heat absorption, and thus achieve a heat-shading effect and reduce glare.

[0038] Optionally, the other ends of the two wings on the same outer wall are arranged to be opposite each other and far apart.

[0039] In this embodiment of the invention, the wing body is elongated and located at the other end away from the square ring-shaped main body, and is opposite to another wing body on the same outer wall. Since there are two wing bodies on the same outer wall, and the opposite end is curved, the wing body can extend more widely in space. As a result, in the structure of multiple monofilaments 2, the distance between the main bodies of adjacent monofilaments 2 is increased, and the air permeability is good.

[0040] In some embodiments, the square ring is rectangular, and the length of the wing on the long side 21 is greater than the length of the wing on the short side 22.

[0041] In this embodiment of the invention, the square ring is set as a rectangle, including a long side 21 and a short side 22. Correspondingly, the length of the wing body connected to the long side 21 needs to be greater than the length of the wing body on the short side 22, so as to ensure that a certain distance can be maintained between adjacent monofilaments 2. The length of the wing body on the long side 21 can be set to 1.5-2 times the length of the wing body on the short side 22, such as the length of the wing body on the short side 22 being 0.3mm and the length of the wing body on the long side 21 being 0.5mm.

[0042] The wing body on the long side 21 has a large length, and the distance between adjacent monofilaments 2 can be guaranteed regardless of which outer wall is close to it, thereby improving air permeability.

[0043] The specific structure of the octagonal star-shaped hollow polyester fiber is described, such as... Figure 2 As shown, the rectangular ring-shaped structure includes a hollow section 20, a long side 21, a short side 22, and wing bodies. Both the long side 21 and the short side 22 are two in number, connected end-to-end to form the ring shape. Eight wing bodies are evenly distributed along the long side 21 and the short side 22, meaning each side has two wing bodies. Each long side 21 has a first wing body 211 and a second wing body 212, and each short side 22 has a third wing body 221 and a fourth wing body 222. The first wing body 211 and the second wing body 212 are of equal length and are longer than the equal-length third wing body 221 and the fourth wing body 222.

[0044] In some embodiments, a method for preparing a warp-knitted fabric as described above includes preparing octagonal star-shaped hollow polyester fiber filaments, which are obtained by using polyethylene terephthalate (PET) through a solution spinning process via a spinneret 1. The spinneret 11 includes a square ring hole and eight slots. The eight slots are evenly distributed on the outer periphery of the square ring hole, and one end of each slot is connected to the four outer sides of the square ring hole. The extension lengths of the slots on adjacent sides of the square ring hole are not equal.

[0045] In this embodiment of the invention, a special-shaped spinneret 11 is used to produce the above-mentioned octagonal star-shaped hollow polyester fiber. The raw material of the polyester fiber can be polyethylene terephthalate, which is melted and then fed into the spinneret 1 through a spinning process for spinning treatment.

[0046] The spinneret 1 is provided with irregularly shaped spinneret holes 11, which mainly consist of two parts. The main part is a square ring hole, corresponding to the square ring body of the hollow polyester fiber, that is, the square ring body of the hollow polyester fiber is ejected from the square ring hole. A slot is also provided on the outer periphery of the square ring hole. One end of the slot is connected to the square ring hole, and the other end is a blind end, extending away from the square ring hole. The position of the slot corresponds to the wing on the hollow polyester fiber, and the wing is ejected from the slot. The extension length of the slot on the outer periphery of the square ring hole is different depending on the length of the wing.

[0047] according to Figure 1 As shown, a spinneret 1 with a diameter of 75-85 mm has several spinneret holes 11. Polyethylene terephthalate is melt-spun through the spinneret holes 11 to form hollow polyester fibers; the cross-sectional shape of each spinneret 11 is similar to that of the spinneret. Figure 2 The diagram shows a matching correspondence, meaning that the cross-sectional shape of the fiber ejected through the spinneret 11 is consistent with... Figure 2The basic structure shown is consistent with that of the one depicted, featuring a square ring-shaped main body and eight wing-shaped bodies.

[0048] The spinneret 11 is distributed on 2-3 sets of concentric circles and is evenly arranged on the same concentric circle. The spinnerets 11 in two adjacent concentric circles are staggered with an angle of 5°~10°. The purpose of the staggered arrangement is to ensure that each monofilament 2 can be cooled evenly and fully, and to prevent the filaments from sticking together.

[0049] In some embodiments, the square annular hole is rectangular, and the four outer sides include two long sides and two short sides; the extension length of the slot communicating with the long sides is greater than the extension length of the slot communicating with the short sides.

[0050] In this embodiment of the invention, the spinneret 11 is defined in detail, and the square ring hole is restricted to be rectangular, corresponding to two long sides and two short sides. In particular, the extension length of the slot on the long side is greater than the length of the slot on the short side. This structure is configured to correspond to the cross-sectional shape of the hollow polyester fiber so that the filaments are compliant with the cross-sectional structure of the hollow polyester fiber.

[0051] More specifically, the diameter of the entire octagonal star-shaped hollow polyester fiber is approximately 1.6-1.7 mm, which is the diameter of the circumference of the outer end of the slot on the relatively long side. The diameter of the circumference of the outer end of the slot on the short side is approximately 1.4-1.5 mm. The ratio of the long side to the short side of the square ring hole is approximately 1.8-2.2:1, with lengths of 1.08-1.76 mm and 0.6-0.8 mm, respectively.

[0052] In some embodiments, the two slots connected on each of the outer sides extend in opposite directions, and the angle between the extension directions of the two slots connected on the short side is set as A, and the angle between the extension directions of the two slots connected on the long side is set as B, satisfying 30°≤A≤40°, 60°≤B≤70°, and A+B=90°-110°.

[0053] In this embodiment of the invention, the spinneret 11 can obtain such... Figure 2 The monofilament 2 structure shown requires that the two slots on the short side of the spinneret 11 extend in opposite directions, with the included angle being smaller than the included angle of the two slots on the long side, to prevent the extruded filaments from sticking together during production. This hole design, on the one hand, creates more obvious grooves, enhancing the capillary wicking effect; on the other hand, it solves the problem of traditional hollow octagonal fibers being easily flattened and collapsed during production. The filaments prepared by this invention have a higher hollow ratio and a more stable hollow structure, improving the warmth retention and heat shielding properties of the fabric.

[0054] In some embodiments, the angle between the extending directions of the slot connected on the short side and the slot that is closer to the adjacent long side is set as C, satisfying 35°≤C≤45°.

[0055] In this embodiment of the invention, the extension angle of two slots that are close to each other on the short and long sides is limited to further prevent the wing bodies ejected on adjacent sides from sticking together.

[0056] The above-mentioned spinneret 11 structure, with its solid central part, ensures the formation of the hollow part 20 of the extruded fiber filament, resulting in a stable hollow structure with a hollow rate of 35%-40%. Compared to the dispersed small hole structure in traditional octagonal polyester fiber filaments, this structure makes it easier to form the hollow part 20 and simplifies the fabrication of the spinneret 1.

[0057] The method for preparing octagonal star-shaped hollow polyester fibers from polyethylene terephthalate (PET) via melt spinning through spinneret 1 includes a PET pellet intrinsic viscosity of 0.80–1.10 dL / g and a terminal carboxyl group content of 15–20 mol / t. The PET raw material is pelletized, dried at 150–155℃ for 7–8 hours, and the moisture content is less than 30 ppm.

[0058] In the spinning process, the screw temperature is 285-305℃, the box temperature is 300-305℃, the speed of the first roller GR1 hot roller is 1800-2100m / min, and the temperature is 80-90℃; the speed of the second roller GR2 hot roller is 3700-4000m / min, and the temperature is 120-127℃; the winding speed is 3650-3960m / min. The process also includes a cooling process, utilizing ring-blowing cooling technology, with a cooling temperature of 15-23℃ and a cooling air velocity of 0.20-0.35m / s, ensuring that each filament is adequately cooled.

[0059] The octagonal star-shaped hollow polyester fiber obtained by the above method has specifications of 40D~75D / 12F~36F, breaking strength ≥4.00cN / dtex, breaking elongation 15%~45%, dyeing uniformity (grey card) grade ≥4.5, and yarn evenness ≤1.5.

[0060] In some embodiments, the first yarn is obtained by physically modifying the octagonal star-shaped hollow polyester fiber filaments: The physical modification treatment includes twisting and feathering the octagonal star-shaped hollow polyester fiber filaments using a ring spinning machine 3. The ring spinning machine 3 includes a front rubber roller 34, a spindle, a yarn tube 38, a sanding roller 39, and a ring rail 37. The sanding roller 39 and the spindle are axially parallel on the ring rail 37, and the yarn tube 30 is sleeved on the spindle. The octagonal star-shaped hollow polyester fiber filaments sequentially contact the front rubber roller 34 and the sanding roller 39, and finally wind onto the yarn tube 38. Both the front rubber roller 34 and the sanding roller 39 rub the outer surface of the octagonal star-shaped hollow polyester fiber filaments, causing the outer surface of the octagonal star-shaped hollow polyester fiber filaments to produce fuzz, which constitutes the first yarn.

[0061] In this embodiment of the invention, the octagonal star-shaped hollow polyester fiber is twisted and feathered using a special ring spinning machine 3 to improve the formation of fine and short feathers on the surface of the first yarn, achieving a cotton-like effect. The octagonal star-shaped hollow polyester fiber filament comprises monofilaments and multifilaments, wherein the multifilament 30 is formed by bundling multiple monofilaments 2.

[0062] like Figure 3 As shown, the ring spinning frame 3 includes a filament guide roller 33, a front roller 35, a front rubber roller 34, a yarn hook 36, a sanding roller 39, a ring rail 37, a traveler, a spindle, and a yarn tube 38. The octagonal star-shaped hollow polyester fiber filaments are unwound from the yarn cake 31 and enter the guide roller 32, then pass through the filament guide roller 33, enter the nip formed by the front roller 35 and the front rubber roller 34, then pass through the guide hook 36, and finally are wound onto the yarn tube 38 in contact with the sanding roller 39. The yarn tube 38 rotates under the drive of the high-speed rotating spindle and slides and twists on the ring rail to form twist.

[0063] When the monofilament 2 or multifilament 30 sequentially contacts the front rubber roller 34 and the abrasive roller 39, it first undergoes relative motion with the front rubber roller 34, rubbing against each other to form fine fuzz. Then, when the filament with the already fine fuzz passes through the abrasive roller 39 again, the high-speed rotating filament air ring makes full contact with the abrasive roller 39, causing short fuzz to form on the filament surface. Therefore, the modified ring spinning machine 3 achieves twisting and fine, short-fuzz yarn, achieving a cotton-like effect. This allows the first yarn to be used directly for weaving without sizing, greatly shortening the processing time and improving production efficiency.

[0064] In some embodiments, the abrasive rollers 39 are provided in multiple forms and are evenly distributed around the spindle.

[0065] In this embodiment of the invention, multiple abrasive rollers 39 are provided and distributed around the spindle. When the filaments of the multifilament body 30 are wound onto the yarn tube 38, they will continuously rub against the surrounding abrasive rollers 39. At the same time, the abrasive rollers 39 can limit the winding position of the filaments and prevent them from coming off.

[0066] In some embodiments, the structure of the ring spinning machine 3 described above can be configured as follows: the front roller 35 has a diameter of 25~27mm, the front rubber roller 34 has a diameter of 30~35mm, a surface roughness Ra of 1.5~12, and a hardness of 70~85 degrees.

[0067] The abrasive roller 39 is installed on the steel ring plate 37 and distributed on both sides of the steel ring. The abrasive roller 39 can rotate flexibly, and the abrasive grain size of the abrasive roller 39 is 500~700 mesh.

[0068] The twisting degree is 10~80 twists / 10cm, and the twisting direction is S-direction or Z-direction. The spindle rotation speed is 20000~25000 rpm. The steel ring is a conical steel ring with a diameter of 40~50mm.

[0069] The steel traveler is selected from the R+F series of Sapphire Bracker. The weight of the steel traveler is 3-4 sizes lighter than that of pure cotton yarn of the same linear density. The purpose is to generate a larger air loop in the yarn, so that the air loop can expand and fully contact the abrasive roller 39 to form hair.

[0070] In this embodiment of the invention, the surface roughness of the front rubber roller 34 is relatively large compared to the corresponding component in a traditional ring spinning machine, which increases the friction on the fiber filaments and promotes the formation of fuzz. Correspondingly, multiple abrasive rollers 39 are arranged around the yarn tube 38. The abrasive rollers 39 are rotating parts with abrasive particles on their outer circumferential surface, which play a role in hairening the fiber filaments, especially with a particle size of 500-700 mesh, which plays a better role in hairening.

[0071] In some embodiments, the multifilament 30 is a Z-twist yarn with a twist of 10~45 twists / 10cm and a twist of 40D~75D / 12F~36F.

[0072] In some embodiments, the method further includes weaving the first yarn A: the first yarn is woven by two Jacquard combs using a complementary open-thread method, wherein one Jacquard comb is used for a threading cycle of threading one multifilament 30 and skipping one needle position, and the other Jacquard comb is used for a threading cycle of threading one needle position and threading one multifilament 30.

[0073] In some embodiments, the method further includes weaving the second yarn B: the polyester low-elasticity yarn is woven by a full-thread method, wherein the full-thread method includes a yarn-threading cycle in which one polyester low-elasticity yarn is threaded through each needle.

[0074] In some embodiments, the polyester low-elasticity yarn is composed of two types of monofilaments with wavy and flat cross sections and circular cross sections, wherein the ratio of the two types of monofilaments with wavy and flat cross sections to circular cross sections is set to 55%~70%:30%~45%.

[0075] In this embodiment of the invention, the fabric structure of the warp-knitted fabric can be prepared in the following manner: The first yarn is made by two Jacquard combs using a complementary open-threading method, with the padding yarn movement structure being 1-0 / 1-2 / / , forming a three-dimensional Jacquard pattern; the complementary open-threading method is as follows: the yarn threading cycle of the first Jacquard comb is (1A, 1*), that is, threading one first yarn and skipping one needle position; the yarn threading cycle of the second Jacquard comb is (1*, 1A), that is, skipping one needle position and threading one first yarn (A). The second yarn is made of polyester low-elasticity yarn with a full-through configuration using a ground comb, and the weft insertion structure is 1-0 / 0-1 / / , forming a stable plain weave with a weft insert. The ground comb is configured with one second yarn per needle in a full-through configuration.

[0076] More specific steps in the preparation method of warp-knitted fabric may include: S1. Warping: Wind the first and second yarns onto the corresponding warp beams respectively: The first yarn is used to warp the first Jacquard comb and the second Jacquard comb respectively. The warping parameters are: 6 yarns are threaded each time, and the warping length is 296 turns. The second yarn is used for ground combing and warping. The warping parameters are: 6 yarns are threaded each time, and the warping length is 592 turns. S2. Warp threading and mounting: Install the warp beams obtained in S1 onto the corresponding guide bars; the first yarn is configured with two Jacquard guides using a complementary open threading method, with the padding yarn movement structure being 1-0 / 1-2 / / , forming a three-dimensional Jacquard pattern; the second yarn is configured with the ground guides fully threaded, with the padding yarn movement structure being 1-0 / 0-1 / / , forming a stable plain weave with weft padding. S3. Weaving: Start the warp knitting machine to weave: The actual warp feed of the first and second Jacquard combs is 1580 mm / rack; the actual warp feed of the ground comb is 1009 mm / rack; S4. Post-processing: Dyeing, setting and finished product inspection of the woven fabric.

[0077] In step S3, the warp feed process parameters are calculated and optimized based on the full-thread benchmark warp feed of 2000 mm / rack, combined with the actual yarn threading density of each guide bar.

[0078] In step S1, the length of the ground comb warp is twice the length of any Jacquard comb warp.

[0079] The present invention has the following beneficial effects: 1. Excellent moisture-wicking and quick-drying properties (capillary effect): The eight wings of different lengths create eight deep grooves on the fiber surface, forming natural capillary channels. This allows for the rapid absorption of liquid sweat and moisture from the skin's surface, which is then diffused and conducted outwards along the grooves to the fabric surface, thus accelerating evaporation and keeping the skin dry and comfortable when worn. Several fibers bundled together can combine to form irregular small grooves, increasing the fabric's breathability. This makes it an ideal choice for sports, outdoor, and summer functional fabrics.

[0080] 2. Excellent warmth retention (hollow structure): The high hollow ratio of this invention allows the hollow structure inside the fiber to lock in still air. Air is a poor conductor of heat, thus forming an effective insulation layer. It is lighter than solid fibers while maintaining the same warmth, achieving a lightweight and warm effect, making it suitable for thermal underwear.

[0081] 3. Excellent heat-shielding performance: The angular cross-section of the eight wings produces multi-angle reflection and scattering of light. Using this principle, sunlight can be reflected back and prevented from shining on us, thus reducing heat absorption and achieving a heat-shielding effect. It can be used in outdoor fabrics in summer, while also reducing glare from the aurora (specular reflection).

[0082] 4. The design of the irregularly shaped spinneret 1 is the most crucial part of the production of octagonal star-shaped hollow polyester fiber filaments. The micropore shape of the spinneret 1 features a rectangular central square ring hole, corresponding to two long sides and two short sides. Notably, the extension length of the slots on the long sides is greater than the length of the slots on the short sides. These eight slots of varying lengths create eight interlaced wings in the produced fiber, increasing the cross-sectional surface area of ​​the filament. At the same denier, the filament diameter is larger, resulting in a lightweight yet thick fabric. Furthermore, the four elongated wings contribute to the fine texture of the fiber, making the fabric fluffy and soft. Simultaneously, the flat rectangular hollow design, combined with the eight wings of varying lengths, forms a stable support structure, solving the problem of easy flattening and collapse of traditional hollow octagonal fibers during production. This invention produces filaments with a higher hollow ratio, further improving the fabric's warmth retention.

[0083] 5. It possesses a cotton-like feel. Octagonal star-shaped hollow polyester fibers are prepared through melt spinning, and then fine, short hairs are formed on the surface of the fibers on a modified ring spinning machine 3. These hairs give the filaments a soft and comfortable cotton-like feel, achieving a cotton-like effect. This shortens the production process, significantly reduces textile costs, increases economic benefits, saves energy, and improves the product's performance and added value. It effectively enhances the product's market competitiveness and brand awareness, and has significant social benefits, making it of great importance. This exemplifies modern textile technology's approach of "endowing materials with new functions through structural design."

[0084] 6. The design, raw material selection, and process optimization of the irregular spinneret 1 of this invention are key to the production of octagonal star-shaped hollow polyester fiber filaments. The spun fibers have high toughness and tensile strength, which effectively guarantees the implementation of subsequent cotton-like processing.

[0085] 7. The second yarn uses a combination of wavy flat and round fibers, which produces a significant synergistic effect. The addition of round fibers effectively neutralizes the dryness of flat fibers, making the fabric more skin-friendly and soft while maintaining a certain degree of crispness. Wavy flat and round cross-section fibers form a large number of capillary pores in the yarn. Wavy flat fibers provide wider gap channels, while round fibers form more uniform tubular channels. This irregular, multi-scale capillary structure can generate a strong wicking effect, quickly absorbing and diffusing sweat from the skin surface to the outer layer of the fabric for rapid evaporation. The surface contact area of ​​wavy flat cross-section fibers is much larger than that of round fibers, providing a cooling sensation upon contact.

[0086] 8. Due to the specific ratio (54% / 46%) of the first yarn being a cotton-like octagonal star hollow polyester long yarn (moisture-wicking, soft) and a polyester DTY (low elasticity, shape retention, cost-effective) with a combination of wavy flat and round cross-section, an optimized balance of function, comfort, and cost is achieved.

[0087] 9. The special combination of complementary open-cut double Jacquard combs (1-0 / 1-2 / / ) + full-cut ground combs (1-0 / 0-1 / / ) is the core technology for forming three-dimensional Jacquard patterns and a stable base.

[0088] The present invention will now be described in detail with reference to specific embodiments.

[0089] Example 1: A method for preparing warp-knitted fabric includes the following steps: Step 1: Raw material preparation. The first yarn A uses octagonal star-shaped hollow polyester fiber filaments. The production of this octagonal star-shaped hollow polyester filament yarn involves selecting PET pellets with an intrinsic viscosity of 0.94 dL / g and an end-carboxyl group content of 18 mol / t. Octagonal star-shaped hollow polyester FDY fibers are prepared using a melt spinning process through a customized octagonal star-shaped spinneret 1. These fibers are then placed on a modified ring spinning machine 3 for twisting and hairization treatment, resulting in a 50D / 24F Z-twist yarn with a twist set at 40 twists / 10cm. This yarn has a uniform, fine, short hair formation on its surface and can be woven directly without sizing, accounting for 54% of the total fabric mass.

[0090] The second yarn B is a polyester low-elasticity yarn with a combination of wavy flat and round cross sections; the polyester low-elasticity yarn with a specification of 40D / 48F is selected, in which the ratio of wavy flat cross section fiber to round cross section fiber is 60%:40%, accounting for 46% of the total fabric weight.

[0091] Step 2: Warping. According to the process requirements, the first yarn and the second yarn are warped separately and wound onto the corresponding warp beams. The warping parameters are as follows: the first and second Jacquard combs are warped separately, both using the first yarn, with 6 yarns threaded each time, and a warping length of 296 turns; the second yarn is warped using a ground comb, with 6 yarns threaded each time, and a warping length of 592 turns (twice the warping length of the Jacquard comb).

[0092] Step 3: Warp threading and machine mounting. Install the prepared warp beams onto the double Jacquard combs and ground combs of the warp knitting machine. Thread the warp using a complementary open threading method: the first Jacquard comb threading cycle is (1A, 1*), the second Jacquard comb threading cycle is (1*, 1A), and the ground combs use a full threading configuration with one yarn B per needle. Set the yarn padding structure for each comb: the yarn padding structure for the double Jacquard combs is 1-0 / 1-2 / / , and the yarn padding structure for the ground combs is 1-0 / 0-1 / / .

[0093] Step 4: Weaving. Start the warp knitting machine and weave according to the optimized warp feed parameters. The actual warp feed of each guide bar is as follows: the warp feed of the first Jacquard and the second Jacquard is 1580 mm / rack; the warp feed of the ground guide bar is 1009 mm / rack. The above-mentioned warp feed rate is based on a full-thread benchmark warp feed rate of 2000 mm / rack, and is calculated and optimized by combining the actual yarn threading density of each guide bar.

[0094] Step 5: Post-processing, 1) Dyeing: Place the woven fabric in a dyeing machine and use disperse dyes for high-temperature and high-pressure dyeing. Control the dyeing temperature at 130℃ and the holding time at 30min to ensure uniform dyeing and color fastness of the fabric; 2) Setting: Send the dyed fabric into a setting machine, set the setting temperature at 170℃ and the machine speed at 25m / min to complete the fabric setting, ensure the fabric's dimensional stability, and improve the shape retention effect.

[0095] The highly comfortable cotton-like warp-knitted fabric prepared in this embodiment combines lightweight warmth, moisture wicking and quick-drying properties, softness against the skin, and slight elasticity and shape retention. It can be directly used to make sportswear, marathon apparel, summer casual T-shirts, home textile fabrics, and other products, meeting the needs of high-end functional textiles.

[0096] Example 2 The difference between this embodiment and Embodiment 1 lies in the adjustment of yarn specifications and weight ratio; the process steps are the same as in Embodiment 1, as follows: For raw material preparation, the first yarn A uses octagonal star hollow polyester fiber filaments and PET pellets. FDY fibers are prepared by melt spinning through a customized octagonal star shaped spinneret 1. After modification, the ring spinning machine 3 is twisted and treated to produce Z-twist yarn with a specification of 40D / 12F. The twist is set to 45 twists / 10cm. The yarn surface has finer hairs, accounting for 50% of the total fabric weight.

[0097] The second yarn B is a combination of wavy flat and round cross-section polyester low-elasticity yarn. It is made of 30D / 36F polyester low-elasticity yarn. The ratio of wavy flat cross-section fiber to round cross-section fiber is 55%:45%, accounting for 50% of the total fabric weight.

[0098] The fabric in this embodiment is lighter and more breathable, making it suitable for producing thin summer T-shirts, sports vests, and other similar products.

[0099] Example 3 The difference between this embodiment and Embodiment 1 lies in the adjustment of the yarn cross-section ratio and post-processing parameters; all other aspects remain the same, as detailed below: First yarn: Specifications and manufacturing process are completely consistent with Example 1 (50D / 24F, 40 twists / 10cm), accounting for 58% of the total fabric weight. Second yarn: Specifications are consistent with Example 1 (40D / 48F), the ratio of wavy flat cross-section fiber to round cross-section fiber is adjusted to 70%:30%, accounting for 42% of the total fabric weight.

[0100] Only the parameters of the post-processing stage were adjusted, and the rest of the process was the same as in Example 1: 1) Dyeing: dyeing temperature 135℃, heat preservation time 35min, the amount of disperse dye was slightly increased to improve the color saturation; 2) Setting: setting temperature 175℃, machine speed 22m / min to enhance the fabric shape retention.

[0101] The fabric in this embodiment has better warmth retention and color fastness, making it suitable for making thermal underwear, winter loungewear, thick casual shirts, and other products.

[0102] Example 4 The difference between this embodiment and Embodiment 1 lies in the twist of the first yarn, with a focus on optimizing the fabric's drape, softness, and colorfastness to meet the specific needs of high-end women's wear and exquisite home textiles. All other parameters remain the same, as detailed below: First yarn: Specifications are the same as in Example 1 (50D / 24F), twist is adjusted to 32 twists / 10cm, reducing twist to improve yarn softness and drape, the intensity of the hairiness treatment is slightly adjusted, the yarn hairiness is uniform and fine, avoiding hair loss, accounting for 54% of the total fabric weight. Second yarn: Specifications, cross-sectional ratio, and weight percentage are the same as in Example 1 (40D / 48F, 60%:40%, 46%), with an additional light smoothing treatment to improve the smoothness of the fabric to the touch.

[0103] Example 5 The difference between this embodiment and Embodiment 1 lies in the yarn specifications; all other parameters remain the same, as detailed below: The first yarn: its specification was adjusted to 75D / 36F, and the preparation process was the same as in Example 1 (octagonal star hollow FDY, twisted, feathered, 40 twists / 10cm), accounting for 56% of the total fabric weight. The second yarn: its specification was adjusted to 50D / 48F, with a 60%:40% ratio of wavy flat cross-section fiber to round cross-section fiber, accounting for 44% of the total fabric weight.

[0104] The fabrics used in all the above embodiments are thick and crisp, suitable for making outerwear, casual wear, running apparel, and other products. Performance tests were conducted on the products of each of the above embodiments, and the results are shown in Tables 1 and 2.

[0105] Table 1

[0106] Table 2

[0107] Tables 1 and 2 show the fabric properties of Examples 1-5.

[0108] The moisture absorption and quick-drying performance tests were conducted according to GB / T 21655.2-2019 "Evaluation of Moisture Absorption and Quick-Drying Properties of Textiles - Part 2: Dynamic Moisture Transfer Method". According to the test standards, moisture absorption meets the requirements of immersion time ≥ 3 and water absorption rate ≥ 3; quick-drying performance meets the requirements of maximum wetting radius of the penetration surface ≥ 3, liquid water diffusion rate of the penetration surface ≥ 3, and unidirectional transfer index ≥ 3. The heat retention rate test method refers to GB / T35762-2017 "Test Method for Thermal Conductivity of Textiles - Plate Method" and FZ / T73022-2019 "Knitted Thermal Underwear". A heat retention rate ≥ 30% indicates good heat retention. Q max The test method refers to GB / T35263-2017 "Test and Evaluation of Instant Cooling Performance of Textiles Upon Contact", when Q max ≥0.15W / cm 2 When the heat-blocking rate is measured, it is determined that the fabric has a cooling sensation upon contact. The test method for heat-blocking rate is in accordance with GB / T 41560-2022 "Determination of heat-blocking performance of textiles". The higher the heat-blocking rate, the better the heat-blocking effect. When the heat-blocking rate is >40%, it is a superior grade of sun protection and heat-blocking functional textile. The test method for color fastness is in accordance with GB / T 3921-2008 "Textiles - Tests for color fastness - Color fastness to washing".

[0109] From the performance tests of the fabrics in Examples 1-5 above, it can be seen that each product has the fluffiness, softness and skin-friendly feel of cotton, the moisture absorption and quick-drying properties of polyester, and good lightweight and heat-blocking properties, making it suitable for use in sportswear, summer casual T-shirts, marathon clothing, home textiles, etc.

[0110] The foregoing description and accompanying drawings fully illustrate embodiments of the invention to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operation may vary. Some portions and features of some embodiments may be included or substituted for portions and features of other embodiments. Embodiments of the invention are not limited to the structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from their scope. The scope of the invention is limited only by the appended claims.

Claims

1. A warp-knitted fabric, characterized in that, It is woven from at least two types of yarns: a first yarn and a second yarn, wherein the first yarn is made of octagonal star-shaped hollow polyester fiber filaments and the second yarn is made of low-elastic polyester filaments; the mass ratio of the first yarn to the second yarn is 50-58:42-50; The monofilament of the octagonal star-shaped hollow polyester fiber has a square ring-shaped cross-section and eight wings on the outer circumferential surface. The eight wing bodies are distributed on the four outer walls of the square ring, and the lengths of the wing bodies on adjacent circumferential outer walls are not equal.

2. The warp-knitted fabric according to claim 1, characterized in that, The wing is elongated, with one end connected to the outer wall and the other end extending away from the outer wall.

3. The warp-knitted fabric according to claim 2, characterized in that, The other ends of the two wings on the same outer wall are set to face away from each other.

4. The warp-knitted fabric according to any one of claims 1-3, characterized in that, The square ring is designed to be rectangular, and the length of the wing body on the longer side is greater than the length of the wing body on the shorter side.

5. A method for preparing warp-knitted fabric as described in claims 1-4, characterized in that, This includes the preparation of octagonal star-shaped hollow polyester fibers, which are produced by using polyethylene terephthalate through a solution spinning process via a spinneret. The spinneret includes a square ring hole and eight slots. The eight slots are evenly distributed on the outer periphery of the square ring hole, and one end of each slot is connected to the four outer sides of the square ring hole. The extension lengths of the slots on adjacent sides of the square ring hole are not equal.

6. The preparation method according to claim 5, characterized in that, It also includes physically modifying the octagonal star-shaped hollow polyester fibers to obtain the first yarn: The physical modification treatment includes twisting and feathering the octagonal star-shaped hollow polyester fiber filaments using a ring spinning machine. The ring spinning machine includes a front rubber roller, a spindle, a yarn tube, a sanding roller, and a ring rail. The sanding roller and the spindle are axially parallel on the ring rail, and the yarn tube is sleeved on the spindle. The octagonal star-shaped hollow polyester fiber filaments sequentially contact the front rubber roller and the sanding roller, and finally wind onto the yarn tube. Both the front rubber roller and the sanding roller rub the outer surface of the octagonal star-shaped hollow polyester fiber filaments, causing the outer surface of the octagonal star-shaped hollow polyester fiber filaments to produce fuzz, which constitutes the first yarn.

7. The preparation method according to claim 6, characterized in that, The surface roughness of the front rubber roller is set to 1.5~12 and the hardness to 70~85 degrees; and / or, the abrasive grain size on the grinding roller is set to 500~700 mesh.

8. The preparation method according to claim 6 or 7, characterized in that, It also includes weaving the first yarn: the first yarn is woven by two Jacquard combs using a complementary open-thread method, wherein the complementary open-thread method includes one Jacquard comb having a yarn-threading cycle of threading one multifilament and skipping one needle position, and the other Jacquard comb having a yarn-threading cycle of skipping one needle position and threading one multifilament.

9. The preparation method according to claim 8, characterized in that, It also includes weaving the second yarn: the polyester low-elasticity yarn is woven by a full-thread method, the full-thread method including a yarn-threading cycle in which one polyester low-elasticity yarn is threaded through each needle.

10. The preparation method according to claim 9, characterized in that, The polyester low-elastic yarn is composed of two types of monofilaments with wavy and flat cross sections and circular cross sections, wherein the ratio of the two types of monofilaments with wavy and flat cross sections to circular cross sections is set at 55%~70%: 30%~45%.

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