A macromesh sandwich fabric and method of weaving the same

Abstract

A kind of big mesh sandwich fabric and its weaving method, including integrated warp knitting forming face layer, intermediate support layer and bottom layer;Face layer includes multiple three-dimensional mesh formed by the knitting of face layer yarn and mesh edge stem around three-dimensional mesh, and mesh edge stem is formed by the continuous knitting of face layer yarn;Intermediate support layer is arranged between face layer and bottom layer, and intermediate support layer includes intermediate connecting yarn, intermediate connecting yarn connects face layer and bottom layer, and intermediate connecting yarn only forms local connecting point in the width direction middle of mesh edge stem;Intermediate connecting yarn is below mesh edge stem in the thickness direction of fabric.The three-layer structure with big mesh, local support and bottom support can be formed without subsequent compounding or bonding, which is beneficial to improve fabric structure stability.

Description

Technical Field

[0001] This application relates to the textile field, specifically to a large-mesh sandwich fabric and its weaving method. Background Technology

[0002] Sandwich fabrics typically consist of a top layer, a middle connecting layer, and a bottom layer, with the three layers forming a single unit through warp knitting. The top layer forms the fabric's appearance and contact surface, the bottom layer provides support, and the middle connecting layer connects the top and bottom layers, creating a space of thickness and elasticity between them.

[0003] In existing sandwich fabrics, to ensure the stability of the connection between the top and bottom layers, the connecting yarns in the middle are usually connected over a large area or densely between the top and bottom layers. While this structure can improve the overall connection strength of the fabric, the following problems can easily occur when forming a large mesh structure: First, the connecting yarns are prone to being exposed in the mesh opening areas, making the surface layer visually cluttered and affecting the cleanliness of the large mesh fabric; Second, the denser connecting yarns will occupy the space through the mesh openings, reducing the fabric's air circulation capacity and making it difficult to fully utilize the breathability advantage of the large mesh fabric.

[0004] In addition, when the mesh size of traditional sandwich fabrics is enlarged, the edge areas surrounding the mesh are affected by uneven tension and support, which can easily lead to loosening, collapse, or local undulations, thus affecting the fabric's stiffness and stability. Summary of the Invention

[0005] In view of the above problems, this application provides a large-mesh sandwich fabric and its weaving method to improve the problems of exposed intermediate connecting yarns and limited mesh permeability space in existing sandwich fabrics when forming a large-mesh structure.

[0006] To achieve the above objectives, the inventors provide a large-mesh sandwich fabric, comprising an integrally warp-knitted surface layer, an intermediate support layer, and a bottom layer;

[0007] The surface layer includes a plurality of three-dimensional meshes woven from surface layer yarns and mesh edge strips surrounding the three-dimensional meshes, wherein the mesh edge strips are continuously woven from the surface layer yarns;

[0008] The intermediate support layer is disposed between the surface layer and the bottom layer. The intermediate support layer includes an intermediate connecting yarn, which connects the surface layer and the bottom layer. The intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strand.

[0009] The intermediate connecting yarn is located below the mesh edge strip in the fabric thickness direction.

[0010] This application also provides a method for weaving a large-mesh sandwich fabric, including:

[0011] The outer layer yarn, the middle connecting yarn, and the bottom layer yarn are warp-knitted as a whole;

[0012] The surface layer is formed by weaving the surface yarn, thereby forming a plurality of three-dimensional mesh holes and mesh edge strips surrounding the three-dimensional mesh holes. The mesh edge strips are formed by continuous weaving of the surface yarn.

[0013] An intermediate support layer is formed by weaving the intermediate connecting yarn between the surface layer and the bottom layer, and the intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strand;

[0014] When forming the local connection point, the intermediate connecting yarn is positioned below the mesh edge strip in the fabric thickness direction;

[0015] The bottom layer is formed by weaving the bottom yarn to obtain the large-mesh sandwich fabric.

[0016] Unlike existing technologies, the large-mesh sandwich fabric and its weaving method provided in this application, by forming multiple three-dimensional meshes and mesh edge strips surrounding the three-dimensional meshes in the surface layer, give the fabric a larger permeability and better breathability. By ensuring that the intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strips, the intermediate connecting yarn is avoided from being widely or densely distributed within the three-dimensional mesh area, thereby reducing the obstruction of the mesh openings by the intermediate connecting yarn and reducing the fabric's heaviness. Simultaneously, the intermediate connecting yarn is located below the mesh edge strips in the fabric's thickness direction, allowing the intermediate connecting yarn to... The mesh edge bands provide concealment, making the mesh less visible when viewed from the surface layer, thus improving the cleanliness and visual consistency of the fabric surface. Furthermore, the local connection points are located in the middle of the width of the mesh edge bands, providing support to the edge areas of the three-dimensional mesh. This ensures that the mesh maintains a relatively stable hole structure even after the aperture is enlarged, reducing the risk of mesh collapse, loosening, or deformation. Moreover, the surface layer, intermediate support layer, and bottom layer are integrally warp-knitted, eliminating the need for subsequent lamination or bonding to form a three-layer structure with large mesh openings, localized support, and bottom layer support, which helps improve the fabric's structural stability.

[0017] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0018] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of the present invention and other related contents, and should not be considered as limitations on this application.

[0019] In the accompanying drawings of the instruction manual:

[0020] Figure 1 This is a diagram showing the movement of the padding yarn in a large-mesh sandwich fabric as described in the embodiment.

[0021] Figure 2 This is a coil structure diagram of a large-mesh sandwich fabric in the embodiment;

[0022] Figure 3 This is a schematic diagram (a) of the surface mesh of a large-mesh sandwich fabric in an embodiment;

[0023] Figure 4 This is a schematic diagram of the position of the middle connecting yarn in the surface layer mesh of a large-mesh sandwich fabric in the embodiment.

[0024] Figure 5 This is a schematic diagram (b) of the surface mesh of a large-mesh sandwich fabric in one embodiment;

[0025] Figure 6 This is a schematic diagram of the bottom layer mesh of a large-mesh sandwich fabric in an embodiment.

[0026] Label Explanation:

[0027] 1. Top layer yarn; 2. Middle connecting yarn; 3. Bottom layer yarn. Detailed Implementation

[0028] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0029] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0030] Please refer to Figure 1 and Figure 2(In the diagram, blue represents the surface yarn, red represents the intermediate connecting yarn, and yellow represents the bottom yarn.) The large-mesh sandwich fabric provided in this application includes an integrally warp-knitted surface layer, an intermediate support layer, and a bottom layer. The surface layer, intermediate support layer, and bottom layer are formed simultaneously through a warp-knitting process, ensuring a continuous yarn connection between the three layers, thereby forming a stable three-layer structure.

[0031] The surface layer comprises multiple three-dimensional mesh openings woven from surface layer yarns and mesh edge strips surrounding these openings. These mesh edge strips are continuously woven from the surface layer yarns. In other words, the mesh edge strips are not independent, added reinforcing strips, but are continuously woven from the surface layer yarns during the warp knitting process. Therefore, the mesh edge strips define the boundaries of the three-dimensional mesh openings, giving them a stable aperture profile.

[0032] Please refer to Figures 3 to 6 The three-dimensional mesh can be circular, diamond-shaped, square, oval, capsule-shaped, or other permeable pore types that can be formed through warp knitting. Different pore types can be achieved by adjusting the yarn path of the guide bars, the yarn threading pattern, or the weave structure. Because the surface layer has multiple three-dimensional meshes, the surface layer as a whole has high porosity and permeability.

[0033] An intermediate support layer is positioned between the top layer and the bottom layer. This intermediate support layer includes a central connecting yarn that connects the top and bottom layers. The central connecting yarn forms a connecting support between the top and bottom layers, maintaining a certain interlayer distance and giving the fabric the thickness and elasticity of a sandwich structure.

[0034] The middle part of the width direction of the mesh edge strip refers to the middle area between the two boundaries of the mesh edge strip in the cross-sectional width direction of a single mesh edge strip. The single mesh edge strip refers to a continuous strip segment located between the intersection of two adjacent strips and extending along the boundary of the three-dimensional large mesh. The local connection point is located in the middle of the width range of the single mesh edge strip itself, rather than in the opening area of ​​the three-dimensional large mesh, the outer edge of the mesh edge strip, or the intersection of two adjacent mesh edge strips. Through this arrangement, the intermediate connecting yarn can be positioned below the mesh edge strip body in the fabric thickness direction, so that the intermediate connecting yarn is concealed by the mesh edge strip and forms a connecting support in the edge strip area of ​​the three-dimensional large mesh, thereby reducing the risk of exposed connecting yarn, yarn stacking at the intersection, and collapse and deformation of the three-dimensional large mesh.

[0035] In other words, the local connection points are not located at the intersection or bend of multiple mesh edge strands, but rather in the area of ​​a single mesh edge strand far from the intersection of the two ends. This limitation prevents the intermediate connecting yarns from concentrating at the intersection, thus avoiding yarn stacking, localized bulges, or mesh corner deformation. Simultaneously, it ensures that the intermediate connecting yarns form a connecting support between the outer and inner layers at the middle section of each strand, thereby improving the stability of the three-dimensional mesh edge region.

[0036] During the weaving process, the surface yarns form a three-dimensional mesh and mesh edge stripes corresponding to the guide bars, and the intermediate connecting yarns connect and weave between the front and back needle beds. Specifically, the position of the intermediate connecting yarn corresponding to the guide bar aligns with the middle of the width direction of the mesh edge stripes in the surface layer. No connection points are formed in the opening areas of the three-dimensional mesh or at the intersections of adjacent mesh edge strips. This results in the intermediate connecting yarn forming only a local connection point in the middle of the width direction of the mesh edge stripes. Since the surface yarns form mesh edge strips at this position, and the connection point of the intermediate connecting yarns on the surface layer side is located below these mesh edge strips, the intermediate connecting yarns are positioned below the mesh edge strips in the fabric thickness direction and can be concealed by them, thus reducing the amount of intermediate connecting yarn exposed from the surface layer side.

[0037] Unlike traditional sandwich fabrics where the connecting yarns are densely distributed over a large area, the connecting yarns in this application form localized connection points only in the middle of the width direction of the edge strands of the mesh. Therefore, the connecting yarns do not create significant obstruction in the opening areas of the three-dimensional mesh, maintaining its permeability while reducing messy yarns on the surface layer.

[0038] The connecting yarn is located below the mesh edge strips in the fabric thickness direction. The fabric thickness direction can be understood as the direction from the surface layer to the bottom layer. By placing the connecting yarn below the mesh edge strips, it is positioned within the space between the surface and bottom layers, rather than being exposed on the surface of the surface layer or within the openings of the three-dimensional mesh. This allows the connecting yarn to be partially obscured or minimized by the mesh edge strips when viewed from the surface layer side, thus improving the overall neatness of the surface layer's appearance.

[0039] In one alternative approach, the local connection point avoids the intersection of two adjacent mesh edge strands. The intersection of two adjacent mesh edge strands is typically a turning point or corner of the mesh boundary, where yarns intersect frequently. If the connecting yarn is also concentrated at this location, it can easily lead to localized yarn stacking or surface bulges. By avoiding the intersection of two adjacent mesh edge strands at the local connection point, yarn stacking at the intersection can be reduced, resulting in a smoother surface.

[0040] In one alternative embodiment, a single three-dimensional mesh is formed by multiple mesh edge strips, and at least one mesh edge strip of each three-dimensional mesh has a local connection point in the middle of its width direction. That is, for each three-dimensional mesh, at least one mesh edge strip around its perimeter has a local connection point for connecting the surface layer and the bottom layer. This structure ensures that each three-dimensional mesh has at least one support position at its edge, reducing the possibility of the three-dimensional mesh collapsing during use or under stress.

[0041] Preferably, each segment of the edge strip corresponding to a single three-dimensional mesh has a local connection point in the middle of its width direction. This provides support to each edge segment of the three-dimensional mesh, further improving the stability of the mesh shape and preventing local collapse or deformation of the large mesh when subjected to tension, compression, or bending.

[0042] In one alternative approach, the intermediate connecting yarn is concealed below the mesh edge strip at the local connection point. Specifically, when the intermediate connecting yarn forms the local connection point, its position is located in the lower region of the mesh edge strip, so that the intermediate connecting yarn is not directly exposed to the opening area of ​​the three-dimensional mesh. Through this positional relationship, the intermediate connecting yarn can be concealed by the mesh edge strip, thereby achieving a balance between connection support and appearance concealment.

[0043] In one alternative approach, the mesh edge strips are formed by continuously weaving the surface yarns using a low-weave, open-weave warp knitting structure. This low-weave, open-weave warp knitting structure allows the mesh edge strips to have a relatively smooth surface while maintaining the softness and permeability of the surface layer. Because the mesh edge strips are formed by continuously weaving the surface yarns, the boundary between the mesh edge strips and the three-dimensional mesh is naturally transitioned, reducing the abruptness of independent reinforcement structures.

[0044] In one alternative approach, the bottom layer comprises bottom layer yarns; specifically, the bottom layer yarns include base yarns and bottom layer support yarns, which are blended to form the bottom layer. The base yarns form the basic weave structure of the bottom layer, while the support yarns enhance its support capacity. By blending the base and support yarns, the planar stability and stiffness of the bottom layer are improved, enabling it to provide stable support for the three-dimensional mesh above.

[0045] In a base layer composed of a blend of base yarns and support yarns, the base yarns form the continuous basic structure, while the support yarns enhance the planar rigidity and shape retention of the base layer. The support yarns can work alongside the base yarns in the base layer weaving, creating a more stable support structure in the fabric's planar direction. When the mesh in the surface layer is compressed, stretched, or bent, the base layer provides reverse support through the connecting yarns, limiting excessive sagging of the mesh edges and reducing the risk of large mesh collapse, loosening of the mesh shape, or deformation after long-term use.

[0046] In one alternative, the surface yarn can be DTY low-elasticity yarn, and the intermediate connecting yarn can also be DTY yarn. DTY yarn has good softness and elasticity, which helps to create a soft, transparent surface effect. In another alternative, the bottom base yarn can be FDY polyester filament, and the bottom support yarn can be monofilament yarn. FDY polyester filament ensures the stability of the bottom base weave, while the monofilament yarn has high rigidity, improving the support performance and anti-collapse ability of the bottom base.

[0047] This application also provides a method for weaving a large-mesh sandwich fabric. This weaving method can be used to prepare the aforementioned large-mesh sandwich fabric.

[0048] The weaving method includes: integrally warp-knitting the face layer yarn, intermediate connecting yarn, and bottom layer yarn; forming a face layer by weaving the face layer yarn, creating multiple three-dimensional mesh openings and mesh edge strips surrounding the three-dimensional mesh openings, the mesh edge strips being continuously woven from the face layer yarn; forming an intermediate support layer by weaving the intermediate connecting yarn between the face layer and the bottom layer, and ensuring that the intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strips; when forming the local connection point, ensuring that the intermediate connecting yarn is located below the mesh edge strips in the fabric thickness direction; and forming a bottom layer by weaving the bottom layer yarn, resulting in a large-mesh sandwich fabric.

[0049] Specifically, a double-needle bed warp knitting machine can be used to knit the face layer yarn, intermediate connecting yarn, and bottom layer yarn in one piece. The face layer yarn is used to form the face layer, the intermediate connecting yarn is used to form the intermediate support layer, and the bottom layer yarn is used to form the bottom layer. Through one-piece warp knitting, the face layer, intermediate support layer, and bottom layer can be formed simultaneously during the weaving process, forming a stable three-layer warp knitting structure.

[0050] During the formation of the surface layer, the surface layer yarns form multiple three-dimensional meshes according to a pre-set warp knitting structure, and mesh edge strips are formed around each three-dimensional mesh. The mesh edge strips are continuously woven from the surface layer yarns, so the mesh edge strips are continuous with the overall structure of the surface layer and do not require separate addition or composite. By adjusting the yarn path, yarn threading pattern, and weave structure of the surface layer yarns, three-dimensional meshes of different shapes and sizes can be formed.

[0051] During the formation of the intermediate support layer, intermediate connecting yarns are woven between the surface layer and the bottom layer to connect them. Unlike methods where the intermediate connecting yarns are densely connected throughout the surface and bottom layers, this application uses intermediate connecting yarns to form localized connection points only in the middle of the width direction of the mesh edge strands. This reduces the obstruction of the three-dimensional mesh openings by the intermediate connecting yarns, resulting in better permeability of the three-dimensional mesh.

[0052] Specifically, local connection points can be formed at the midpoint of the width direction of a single mesh edge strip. For each three-dimensional mesh, a local connection point can be formed at the midpoint of the width direction of at least one mesh edge strip, or local connection points can be formed at the midpoint of the width direction of each mesh edge strip. Through this method, the number and distribution density of local connection points can be adjusted according to the fabric support requirements.

[0053] When forming local connection points, the intermediate connecting yarn is positioned below the mesh edge strips. In other words, the intermediate connecting yarn is located below the mesh edge strips of the surface layer in the fabric thickness direction, and is situated within the interlayer space between the surface layer and the bottom layer. In this way, the intermediate connecting yarn can be concealed by the mesh edge strips and is not easily exposed when viewed from the surface layer side.

[0054] Furthermore, the connection points can be made to avoid the intersection of the edge strands of two adjacent meshes. This reduces yarn accumulation at the intersection points, avoids local bulges or a messy appearance, and improves the smoothness of the fabric surface.

[0055] The bottom layer is formed by warp knitting of the bottom layer yarns. It lies beneath the intermediate support layer and is connected to the top layer via connecting yarns. The bottom layer can be formed from a single bottom layer yarn or from a blend of bottom base yarns and bottom support yarns. When the bottom layer is formed from a blend of bottom base yarns and bottom support yarns, it achieves better planar stiffness and support, thus providing anti-collapse support for the three-dimensional mesh.

[0056] The above weaving method allows for the formation of a sandwich fabric with three-dimensional mesh, mesh edge bands, local connecting points, and a bottom layer during the integrated warp knitting process. This method ensures the permeability of the large mesh openings in the surface layer while providing support for the edges of the three-dimensional mesh at the local connecting points, and positions the middle connecting yarn below the mesh edge bands, thereby reducing the exposure of the connecting yarn.

[0057] In one specific weaving method, the surface layer, intermediate support layer, and bottom layer can be woven together using a double-needle-bed warp knitting machine. The surface layer yarn can be made of polyester low-elasticity yarn to form a soft and breathable surface layer; the intermediate connecting yarn can be made of polyester elastic yarn to form a connecting support between the surface layer and the bottom layer; the bottom layer yarn can include polyester filament and polyester monofilament, so that the bottom layer has both basic weaving stability and supporting rigidity.

[0058] During weaving, multiple three-dimensional meshes are first formed in the surface area by the surface yarn, and then the mesh edge strips are formed around the three-dimensional meshes through continuous weaving. The mesh edge strips extend along the boundary of the three-dimensional meshes, giving each three-dimensional mesh a clear and stable hole shape outline.

[0059] Subsequently, the intermediate connecting yarn is woven between the surface layer and the bottom layer. Instead of densely connecting across the entire mesh area, the intermediate connecting yarn forms localized connection points in the middle of the width of the mesh edge strands. These localized connection points are located in the middle section of the mesh edge strands, avoiding the intersections of adjacent mesh edge strands. This allows the intermediate connecting yarn to support the edges of the three-dimensional mesh without concentrating at mesh intersections.

[0060] Meanwhile, when forming local connection points, the intermediate connecting yarn is located below the mesh edge strip in the fabric thickness direction. Since the mesh edge strip is on the surface layer and covers the intermediate connecting yarn below, when viewed from the surface layer side, the intermediate connecting yarn is not easily exposed in the three-dimensional mesh area, and the surface layer presents a relatively clean, low-profile, transparent effect.

[0061] The bottom layer is woven from bottom layer yarns. In one specific configuration, the bottom layer is formed by blending bottom layer base yarns and bottom layer support yarns. The bottom layer base yarns ensure the basic structural stability of the bottom layer, while the bottom layer support yarns enhance its rigidity and stiffness. Due to the good support capacity of the bottom layer, even if the surface layer forms a large three-dimensional mesh, the risk of large mesh collapse can be reduced by the combined effect of the bottom layer and the intermediate support layer.

[0062] Example:

[0063] The large-mesh sandwich fabric is a warp-knitted, three-dimensional, lightweight sandwich fabric. It is formed by warp knitting an integrally with a face layer, a middle support layer, and a bottom layer. The face layer is the mesh layer, the middle support layer includes connecting yarns, and the bottom layer is a permeable layer. The face layer forms multiple three-dimensional mesh openings and the edge bands that surround these openings. The connecting yarns connect the face layer and the bottom layer, and the bottom layer provides support for the face layer and the three-dimensional mesh openings.

[0064] In this embodiment, the surface layer and the intermediate connecting yarn are both made of 30D / 36F polyester elastic yarn, while the main material of the bottom layer is 50D / 72F polyester filament and 30D / 1F polyester monofilament. The 30D / 36F polyester elastic yarn is used to give the surface layer a soft, thin, and transparent surface effect, and to give the intermediate connecting yarn appropriate elastic bonding properties. The 50D / 72F polyester filament is used to form the basic structure of the bottom layer, and the 30D / 1F polyester monofilament is used to improve the supporting rigidity and shaping ability of the bottom layer, thereby enabling the bottom layer to form anti-collapse support for the three-dimensional mesh in the surface layer.

[0065] The warp-knitted three-dimensional mesh lightweight sandwich fabric in this embodiment has a warp density of 22 cpc and a weight of less than 150 g / m². By controlling the warp density and weight, the fabric maintains the supporting performance of the sandwich structure while possessing good lightness and breathability.

[0066] This embodiment uses a warp-knitted jacquard double-needle-bed double-jakka warp knitting machine, size E28, with 7 guide bars. The double-needle-bed structure allows for the separate formation of the surface and underlayers during weaving, with an intermediate support layer formed between them by connecting yarns. Through the interplay of Jakka guide bars and ground guide bars, multiple three-dimensional mesh openings and edge bands surrounding these openings are formed in the surface layer, with the connecting yarns creating localized connection points in the width of these edge bands.

[0067] Specifically, in this embodiment, the weave padding yarn number, warp threading method, and warp feed amount for each guide bar are as follows:

[0068] GB2 is used for weaving intermediate connecting yarns, with a padding yarn number of 1-0 / 0-1 / 1-0 / 0-1 / / , a warp threading pattern of 2 threads through 6 loops, and a warp feed of 4300mm. The intermediate connecting yarn corresponding to GB2 is woven between the front and back needle beds to form an intermediate support layer connecting the top and bottom layers. The 2-thread-6-loop warp threading pattern ensures that the intermediate connecting yarn is not densely distributed throughout the entire top layer area, but rather participates in the connection locally. This allows for the formation of local connection points in the middle of the width direction of the mesh edge strands, reducing the obstruction of the three-dimensional mesh opening area by the intermediate connecting yarn.

[0069] JB3.1 is used for the mesh layer of the woven surface, with a backing yarn code of 1-0 / 1-1 / 1-2 / 1-1 / / , a warp insertion method of 1C1, and a warp feed of 1350mm. JB3.2 is used for the mesh layer of the woven surface, with a backing yarn code of 1-0 / 1-1 / 1-2 / 1-1 / / , a warp insertion method of 1C1, and a warp feed of 1400mm.

[0070] JB4.1 is used for the mesh layer of the woven surface, with the padding yarn number being 1-2 / 1-1 / 1-0 / 1-1 / / , the warp insertion method being 1C1, and the warp feed being 1400mm.

[0071] JB4.2 is used for the mesh layer of the woven surface, with the padding yarn number being 1-2 / 1-1 / 1-0 / 1-1 / / , the warp insertion method being 1C1, and the warp feed amount being 1350mm.

[0072] The aforementioned JB3.1, JB3.2, JB4.1, and JB4.2 work together to weave the surface layer, creating multiple three-dimensional mesh openings and forming continuous mesh edge strips between adjacent openings. Since these mesh edge strips are continuously woven from the surface layer yarns, they define the boundaries of the three-dimensional mesh openings and provide corresponding shielding positions for the local connection points of the intermediate connecting yarns.

[0073] GB7 is used for weaving the bottom permeable layer, with a padding yarn code of 1-0 / 1-2 / / , a full-length warp thread, and a warp feed of 1300mm. GB8 is also used for weaving the bottom permeable layer, with a padding yarn code of 1-0 / 0-1 / / , a full-length warp thread, and a warp feed of 1050mm. GB7 and GB8 together form the bottom permeable layer, in which the polyester filaments in the bottom layer form the basic structure, and the polyester monofilaments enhance the stiffness and support of the bottom layer, creating a stable support structure in the fabric plane.

[0074] During the weaving process, the surface yarns form the mesh layer and mesh edge strands through JB3.1, JB3.2, JB4.1, and JB4.2; the intermediate connecting yarns connect the surface and bottom layers through GB2. Because GB2 uses a 2-thread, 6-hole partial warp-threading method and coordinates with the surface mesh structure, the connection position of the intermediate connecting yarn corresponds to the middle of the width direction of the mesh edge strands, not to the opening area of ​​the three-dimensional mesh. Therefore, the intermediate connecting yarns only form a local connection point in the middle of the width direction of the mesh edge strands.

[0075] Meanwhile, when forming local connection points, the intermediate connecting yarn is located below the mesh edge strip in the fabric thickness direction. In other words, the connection point of the intermediate connecting yarn on the surface layer side is located below the mesh edge strip and is concealed by the mesh edge strip in the surface layer. Thus, when viewed from the surface layer side, the intermediate connecting yarn is less likely to be exposed in the opening area of ​​the three-dimensional mesh, reducing yarn exposure and maintaining a low-weave, transparent, and clean appearance.

[0076] The warp-knitted three-dimensional mesh lightweight sandwich fabric obtained through the above weaving method can form a stable three-dimensional mesh structure on the surface layer; the middle connecting yarn supports the edge areas of the three-dimensional mesh through local connection points, reducing the risk of large mesh collapse or hole deformation; the bottom permeable layer improves the overall stiffness and anti-collapse ability of the fabric through the combination of polyester filaments and polyester monofilaments. Therefore, this fabric can combine the effects of being lightweight, breathable, having hidden connecting yarns, stable hole structure, and a neat appearance.

[0077] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A large-mesh sandwich fabric, characterized in that, It includes an integrally warp-knitted surface layer, intermediate support layer, and bottom layer; The surface layer includes a plurality of three-dimensional meshes woven from surface layer yarns and mesh edge strips surrounding the three-dimensional meshes, wherein the mesh edge strips are continuously woven from the surface layer yarns; The intermediate support layer is disposed between the surface layer and the bottom layer. The intermediate support layer includes an intermediate connecting yarn that connects the surface layer and the bottom layer. The intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strip. The intermediate connecting yarn is located below the mesh edge strip in the fabric thickness direction.

2. The large-mesh sandwich fabric according to claim 1, characterized in that, The local connection point avoids the intersection of two adjacent mesh edge strands.

3. The large-mesh sandwich fabric according to claim 1, characterized in that, Each of the three-dimensional mesh openings is formed by multiple mesh edge strips, and each of the three-dimensional mesh openings has a local connection point formed in the middle of the width direction of at least one of the mesh edge strips.

4. The large-mesh sandwich fabric according to claim 3, characterized in that, Each segment of the edge strip corresponding to a single three-dimensional mesh has a local connection point formed in the middle of its width direction.

5. The large-mesh sandwich fabric according to claim 1, characterized in that, The intermediate connecting yarn is concealed below the mesh edge strip at the local connection point.

6. The large-mesh sandwich fabric according to claim 1, characterized in that, The mesh edge strips are formed by continuous weaving of the surface yarn using a low-weave, open warp-knitting structure.

7. The large-mesh sandwich fabric according to claim 1, characterized in that, The bottom layer includes a base yarn and a support yarn, which are interwoven to form the bottom layer.

8. A method for weaving a large-mesh sandwich fabric, characterized in that, include: The outer layer yarn, the middle connecting yarn, and the bottom layer yarn are warp-knitted as a whole; The surface layer is formed by weaving the surface yarn, thereby forming a plurality of three-dimensional mesh holes and mesh edge strips surrounding the three-dimensional mesh holes. The mesh edge strips are formed by continuous weaving of the surface yarn. An intermediate support layer is formed by weaving the intermediate connecting yarn between the surface layer and the bottom layer, and the intermediate connecting yarn forms a local connection point only in the middle of the width direction of the mesh edge strand; When forming the local connection point, the intermediate connecting yarn is positioned below the mesh edge strip in the fabric thickness direction; The bottom layer is formed by weaving the bottom yarn to obtain the large-mesh sandwich fabric.

Images