A melt-reinforced double needle bed warp knit mesh fabric and method of making same

Abstract

The application discloses a kind of fused reinforced double needle bed warp knitted mesh and its manufacturing method, and the first fabric layer and the second fabric layer of relatively arranged are woven by double needle bed warp knitting machine, and hot melt yarn is woven in the weaving process of at least one fabric layer, to form warp knitted mesh base cloth;The warp knitted mesh base cloth is heat set, so that the hot melt yarn melts and covers the loop column and / or loop arc of the corresponding fabric layer outer surface, to form fused reinforcement structure;After cooling, the fused reinforcement structure solidifies in the warp knitted mesh.The application can form targeted protection to the outer side loop of double needle bed warp knitted mesh, reduce the wear and tear and breakage of surface loop, improve the wear resistance and service life of double needle bed warp knitted mesh.

Description

Technical Field

[0001] This application relates to the textile field, specifically to a melt-reinforced double needle bed warp-knitted mesh fabric and its manufacturing method. Background Technology

[0002] Double-needle-bed warp-knitted mesh fabrics are typically woven using needle beds arranged in opposite directions to form double-layer or sandwich fabrics. These fabrics are characterized by good breathability, strong three-dimensionality, and light weight, and can be used in footwear, sporting goods, home furnishings, and other textile products requiring breathability, cushioning, or support.

[0003] The outer layer of a double-needle-bed warp-knitted mesh fabric can employ a mesh structure, forming multiple mesh openings through loops and corresponding yarn segments. Compared to plain weave fabrics with a more continuous structure, the yarn density within the mesh area is lower. Under continuous friction, the frictional load tends to concentrate on the local yarns constituting the mesh openings and their surrounding areas. As the number of friction cycles increases, the yarns on the fabric surface are prone to pilling, wear, and even breakage. Local yarn breakage may further cause the mesh openings to enlarge or the fabric to crack.

[0004] Especially for double-needle bed warp-knitted mesh fabrics, different outer layers can use different yarns, weave structures, or padding methods, resulting in differences in abrasion resistance on both sides of the fabric. When the side with lower abrasion resistance is used as the friction contact surface for a long time, the yarns on that side may wear or break before the other side, thus affecting the service life of the entire double-needle bed warp-knitted mesh fabric. Summary of the Invention

[0005] In view of the above problems, this application provides a method for manufacturing a melt-reinforced double-needle bed warp-knitted mesh, which solves the problem that the outer layer of the double-needle bed warp-knitted mesh is prone to local coil wear and breakage under continuous friction.

[0006] To achieve the above objectives, this application provides a method for manufacturing a melt-reinforced double-needle-bed warp-knitted mesh, comprising:

[0007] A first and second woven layers are formed by knitting with a double needle bed warp knitting machine, and hot melt yarn is woven into at least one woven layer to form a warp-knitted mesh fabric.

[0008] The warp-knitted mesh fabric is heat-set to melt the hot melt wire and cover the coil columns and / or coil arcs on the outer surface of the corresponding weave layer, forming a melt-reinforced structure.

[0009] In the warp-knitted mesh fabric that has been cooled after heat setting, the melt-reinforced structure solidifies to obtain a melt-reinforced double-needle bed warp-knitted mesh fabric.

[0010] This application also provides a melt-reinforced double-needle-bed warp-knitted mesh fabric, which is manufactured using the above-described method for manufacturing melt-reinforced double-needle-bed warp-knitted mesh fabric.

[0011] Unlike existing technologies, the above-mentioned technical solution incorporates hot melt yarns during the weaving process of at least one outer layer, allowing the hot melt yarns to be held in the corresponding layer by the warp knitting structure before heat setting. During heat setting, the hot melt yarns melt from their yarn state and cover the coil posts and / or coil arcs based on the coil structure of the corresponding layer; after the molten material solidifies, it forms a molten reinforcement structure bonded to the coil.

[0012] Because the first and second layers of a double-needle-bed warp-knitted fabric are formed by loops from corresponding needle beds, the outer surface of the fabric mainly consists of loop posts and loop arcs. The extension threads connecting the loops and the connecting yarns between the first and second layers are located inside the fabric. Therefore, molten material is more easily deposited in the loop areas that directly bear external friction, forming a molten reinforced structure. By covering and protecting the loop posts and loop arcs with molten material, the frictional load acting directly on the original yarn can be reduced, decreasing the likelihood of loop pilling, wear, and breakage. This improves the abrasion resistance and service life of the outer layer of the double-needle-bed warp-knitted mesh.

[0013] 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

[0014] 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.

[0015] In the accompanying drawings of the instruction manual:

[0016] Figure 1 This is a schematic diagram of the mesh layer of a melt-reinforced double needle bed warp-knitted mesh fabric in one embodiment;

[0017] The reference numerals used in the above figures are explained as follows:

[0018] 1. Main yarn; 2. Connecting yarn; 3. Hot melt yarn. Detailed Implementation

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

[0020] Please refer to Figure 1 This embodiment provides a method for manufacturing a melt-reinforced double needle bed warp-knitted mesh fabric, including steps S100 to S300.

[0021] S100 is formed by knitting a first and second layer with opposite orientation using a double needle bed warp knitting machine, and hot melt yarn 3 is woven into at least one layer during the knitting process to form a warp-knitted mesh fabric.

[0022] A double-needle bed warp knitting machine has a front needle bed and a rear needle bed that are configured opposite to each other. The front needle bed and the rear needle bed respectively padded the yarn through corresponding guide bars, so that the yarn formed loops on the two needle beds respectively, thereby forming a first layer and a second layer that are arranged opposite to each other along the thickness direction of the fabric.

[0023] The first and second layers can employ the same or different warp knitting structures. For example, one layer can form a mesh structure with multiple openings, while the other layer can form a mesh structure or a relatively dense fabric structure, thus creating different surface structures according to the actual application requirements of the double-needle bed warp-knitted mesh.

[0024] The hot melt yarn 3 participates in warp knitting simultaneously during the weaving process of at least one of the first and second weave layers. Here, "simultaneous participation in warp knitting" means that the hot melt yarn 3 is not attached to the fabric surface by coating, bonding, or spraying after the first and second weave layers are completed, but rather forms the warp knitting structure together with the body yarn 1 that forms the corresponding weave layer through the padding movement of the corresponding guide bar.

[0025] Before heat setting, the hot melt yarn 3 maintains its yarn state, allowing it to participate in warp knitting according to a predetermined padding path, and remains in the corresponding weave layer through its own loops and the organizational relationship with the main yarn 1. Thus, the position of the hot melt yarn 3 in the double-needle bed warp-knitted mesh fabric can be predetermined, ensuring that it primarily acts on the pre-configured weave layer area during subsequent melting.

[0026] The hot melt yarn 3 can be made of thermoplastic functional yarn, such as polyester hot melt yarn 3. The hot melt yarn 3 can maintain the yarn shape in the normal weaving state, soften or melt after reaching the corresponding heat setting conditions, and can combine with the adjacent body yarn 1, and solidify after cooling.

[0027] It is understood that the warp-knitted double needle bed mesh fabric mentioned above is a fabric with a fixed structure woven only by a double needle bed warp knitting machine. The fixed structure refers to a fabric structure with a face layer, a bottom layer, and a connecting layer.

[0028] By directly weaving hot melt yarn 3 into the warp knitting process, the position of hot melt yarn 3 can be constrained by the warp knitting structure itself, so that the subsequently formed molten reinforcement structure corresponds to the weave layer that needs to improve wear resistance. This makes it easier for the molten material to stack in the coil area that directly bears external friction, thus enhancing the protective effect.

[0029] S110, a connecting yarn 2 is woven between the first weave layer and the second weave layer, the connecting yarn 2 connecting the first weave layer and the second weave layer, and forming an intermediate layer between them.

[0030] In one embodiment, while the first and second layers are formed on the front and rear needle beds respectively, the connecting yarn 2 is alternately padded between the front and rear needle beds by corresponding comb bars, thereby connecting the first and second layers.

[0031] The connecting yarn 2 can extend along the fabric thickness direction or the inclined direction between the first and second weave layers, so that the two outer weave layers maintain a predetermined distance and form an intermediate layer between them, thereby forming a double needle bed warp-knitted mesh.

[0032] The connecting yarn 2 can be made of appropriate materials according to the required thickness, support performance, and resilience. For example, a monofilament with a certain stiffness or elasticity can be used to form the intermediate layer so as to maintain a stable spatial interval between the first and second weave layers.

[0033] By setting a connecting yarn 2 between the first and second fabric layers, the two fabric layers can form an integral double needle bed warp knitting structure. At the same time, the connecting yarn 2 is mainly distributed inside the fabric, avoiding the connecting yarn 2 becoming the main friction bearing part on the fabric surface.

[0034] S120, at least one of the first fabric layer and the second fabric layer is a mesh fabric layer with multiple mesh openings, and the outer surface of the mesh fabric layer is composed of multiple loops woven from corresponding needle beds.

[0035] The mesh layer can be formed by the main yarn 1 according to a predetermined padding structure to create multiple spaced mesh openings. The shape, size, and arrangement of the mesh openings can be adjusted by the padding path of the corresponding guide bar and the jacquard control method.

[0036] During double-needle-bed knitting, multiple loops are formed by the needles on the corresponding needle bed, and these loops form the main structure of the mesh layer along the warp and weft directions. Since one side of this layer faces the outside of the double-needle-bed warp-knitted mesh, the loops formed on the corresponding needle bed constitute the main yarn structure of the outer surface of the mesh layer.

[0037] When the mesh layer is subjected to external friction, the external friction components first contact and act on the coils located on the outer surface of the mesh layer. Therefore, compared with the yarn segments located inside the fabric, the outer coils are more likely to withstand frictional loads over a long period of time.

[0038] By clearly defining that the outer surface of the mesh layer is composed of coils formed by corresponding needle beds, a correspondence can be established between the melting position of the subsequent hot melt wire 3 and the actual friction-bearing position, so as to reinforce the outer coils.

[0039] S130, the body yarn 1 forming the mesh layer includes a coil and an extension line connecting adjacent coils, the coil post and coil arc facing the outer surface of the mesh layer, and the extension line facing between the first weave layer and the second weave layer.

[0040] In warp knitting, the main yarn 1 is looped by knitting needles to form loops, and the nesting of loops forms the warp knitting structure. The warp knitting loop is mainly divided into two parts: the loop body and the extension yarn. The loop body is the loop-shaped part of the loop, which can be divided into loop arcs and loop columns.

[0041] In the double-needle-bed warp knitting structure of this embodiment, the front needle bed and the rear needle bed are arranged opposite to each other, each forming loops in the corresponding fabric layer. The loop posts and loop arcs forming the outer surfaces of the first and second fabric layers mainly face outwards, while at least a portion of the extension yarns in the corresponding body yarn 1 face between the first and second fabric layers. In some embodiments, all the extension yarns in the corresponding body yarn 1 face between the first and second fabric layers.

[0042] Meanwhile, the connecting yarn 2, which connects the first and second fabric layers, is also mainly located between the two fabric layers. Therefore, when viewed from the outer surface of the double-needle bed warp-knitted mesh, the exposed and directly rubbed parts are mainly the loop posts and loop arcs, while the extension yarns and connecting yarn 2 are shielded by the structure of the first and second fabric layers themselves.

[0043] The loops and loops have a more curved yarn profile compared to the linearly extending extension yarn. After the hot melt yarn 3 melts, the loop area provides more contact and holding space for the molten material, making it easier for the molten material to cover the vicinity of the loops and loops.

[0044] Therefore, matching the main coverage area of ​​the hot melt material with the area of ​​the double needle bed warp-knitted mesh that actually bears surface friction can improve the effective protection of the outer fabric layer by the hot melt material.

[0045] S140, at least one independent comb is used to weave a protective structure with hot melt wire 3, so that the hot melt wire 3 is evenly distributed in the loops formed by the main yarn in the mesh layer, so that the hot melt wire forms a uniform cured covering structure in the mesh layer after subsequent heat setting.

[0046] In one embodiment, hot melt yarn 3 is used with at least one independent comb, and body yarn 1 forming the mesh layer is used with another comb.

[0047] The hot melt wire 3 comb can independently control the padding path, warp threading method and warp feed amount of the hot melt wire 3, so as to configure the hot melt wire 3 according to the position of the coil that needs to be reinforced in the mesh layer.

[0048] In some embodiments, the hot melt wire 3 itself can form a loop on the corresponding needle bed, so that the hot melt wire 3 loop and the body yarn 1 loop form a crossing or nesting relationship at the same or adjacent needle positions. In another embodiment, the hot melt wire 3 is used to knit a weft-supporting structure, which does not participate in loop formation, but is in contact with the loop formed by the body yarn 1.

[0049] In one specific embodiment, the hot melt yarn 3 comb bar can form loops using a 0-0 / 1-1 / / padding structure. This padding method allows the hot melt yarn 3 to form a stable loop structure near the corresponding needle position and to contact the loops of the body yarn 1 of the mesh layer.

[0050] By using independent hot melt wire 3 combs, the hot melt wire 3 can be accurately positioned in the coil area that directly bears external friction without changing the basic working mode of the body yarn 1 comb that forms the main structure of the mesh layer.

[0051] S150, the hot melt yarn 3 is woven into the first or second weave layer, so that the melt-reinforced structure is formed on one side surface of the double needle bed warp-knitted mesh.

[0052] In some double-needle bed warp-knitted meshes, the first and second layers have different structures or usage conditions, resulting in different abrasion resistance on the two outer surfaces. For example, one layer may serve as the primary friction contact surface in actual use, while the other layer primarily acts as the inner support surface.

[0053] In this case, the hot melt wire 3 can be woven into only the first layer and not into the second layer; or the hot melt wire 3 can be woven into only the second layer and not into the first layer.

[0054] Specifically, the placement of the hot melt wire 3 can be determined based on the wear resistance of the first and second layers or the direction of frictional contact during actual use. For example, the hot melt wire 3 can be placed in a layer with relatively low wear resistance or one that is expected to withstand a high frictional load.

[0055] By selectively melting and reinforcing only one outer surface of the double-needle bed warp-knitted mesh, the abrasion resistance of easily worn surfaces can be improved while reducing the overall amount of hot melt wire 3 used and minimizing the impact on the original softness, breathability, or surface feel of the other layer.

[0056] S200, the warp-knitted mesh fabric is heat-set so that the hot melt wire 3 melts and covers the coil columns and / or coil arcs on the outer surface of the corresponding weave layer to form a melt-reinforced structure.

[0057] After the double-needle bed warp-knitted mesh fabric is woven, it is heat-set.

[0058] The heat setting conditions are set according to the melting characteristics of the hot melt wire 3 used, so that the hot melt wire 3 melts from its original yarn state.

[0059] Since the hot melt wire 3 has been woven together with the body yarn 1 of the corresponding fabric layer in step S100 and is held in the coil area of ​​the mesh layer by the mutual nesting between the coils, the molten material is supported by the coil of the adjacent body yarn 1 after the hot melt wire 3 melts.

[0060] Compared to a generally linearly extending yarn, a coil consisting of loops and arcs has a curved yarn path, and adjacent coils are arranged continuously on the coil surface. Therefore, the molten hot melt material can be retained and cover at least part of the surface of the loops and arcs.

[0061] The covering here does not require the molten hot melt material to completely surround the entire circumferential surface of the cylinder or arc, nor does it require the formation of a continuous molten film layer on the entire fabric surface. Rather, it refers to the molten hot melt material adhering to at least a portion of the outer surface of the cylinder and / or arc and bonding with the corresponding body yarn 1.

[0062] After cooling and solidification, the molten material forms a molten reinforced structure, so that the main yarn 1, which was originally directly exposed to the fabric surface, is at least partially covered by the solidified hot-melt material. When external friction components come into contact with the mesh layer, the molten reinforced structure can at least partially bear or disperse the frictional force, thereby reducing the degree to which the main yarn 1 is directly and continuously rubbed.

[0063] S210, the molten hot-melt wire 3 after heat setting is attached to the outside of the coil post and the coil arc, and covers at least a portion of the surface of the coil post and the coil arc, so that the molten reinforcement structure is located on the side of the mesh layer that bears external friction.

[0064] The loops and arcs on the outer surface of the mesh layer are the main contact structures when the double-needle bed warp-knitted mesh rubs against external objects. After the hot melt wire 3 melts in the corresponding weave layer, the molten material is distributed along the surface of the adjacent loops, causing the molten material to adhere to the side of the loops and arcs facing outwards.

[0065] In one embodiment, the hot melt material can cover a portion of the ring column, a portion of the ring arc, or both the ring column and the ring arc simultaneously.

[0066] The molten material formed at different coil locations can be independent of each other or locally connected at adjacent locations. Regardless of the specific form, the molten reinforcement structure is mainly formed on the side of the mesh layer facing the external friction environment, rather than in the middle region between the first and second layers.

[0067] When the double needle bed warp-knitted mesh is subjected to friction, the melt-reinforced structure can preferentially contact the friction component, reducing the direct action of the friction component on the loops and arcs of the main yarn 1, thereby reducing the possibility of fiber fuzzing, yarn thinning, and eventual breakage of the surface loops due to long-term friction.

[0068] Meanwhile, since the reinforcement is concentrated in the outer coil area that actually bears the friction, there is no need to put a large amount of hot melt material between the first and second layers, which can effectively reduce the waste of hot melt wire and improve its utilization rate.

[0069] S220, during the heat setting process, the molten hot melt wire 3 spreads along the curved contour of the ring column and the ring arc, and after cooling, forms a solidified covering structure that is combined with the ring column and the ring arc.

[0070] During the heat setting process, the hot melt wire 3 gradually transforms from a solid yarn into a molten material that can spread along the surface of adjacent yarns.

[0071] Since the hot melt wire 3 is held near the coil by the warp knitting structure before heat setting, the molten material can directly adhere to the coil columns and coil arcs nested with it.

[0072] The cylinder and the arc have a continuous curved profile. After the molten material covers along the curved profile, one or more covered areas can be formed on the surface of the cylinder or the arc.

[0073] The curing cover structure here can be intermittently covered depending on the amount of hot melt wire 3 used, the coil density, and the specific heat setting state, as long as it can be combined with the coil post and / or coil arc and form wear-resistant protection for them.

[0074] By allowing the molten material to form a solidified covering structure based on the curved contour of the original coil, the surface coil can be locally reinforced while maintaining the original structure of the double-needle bed warp-knitted mesh, thus avoiding the large-area hardening that may occur when using an overall surface coating.

[0075] S300, in the warp-knitted mesh fabric cooled after heat setting, the melt-reinforced structure solidifies to obtain a melt-reinforced double-needle-bed warp-knitted mesh fabric.

[0076] As the temperature decreases, the molten material attached to the surface of the cylinder and the arc gradually solidifies and maintains its bond with the corresponding body yarn 1, thereby forming a stable molten reinforced structure.

[0077] After the molten reinforcement structure is formed, the original body yarns 1 of the loop column and loop arc, together with the solidified hot melt material, constitute the outer friction bearing area of ​​the mesh layer. Under the action of friction, the solidified hot melt material can cover and protect the original body yarns 1, making the body yarns 1 less prone to wear or breakage due to local continuous friction.

[0078] The resulting double-needle bed warp-knitted mesh retains the original double-needle bed structure formed by the first layer, the second layer, and the intermediate connecting structure, while also forming a fused reinforcement structure in the outer loop area of ​​at least one layer, thereby improving the abrasion resistance of the corresponding layer.

[0079] Example 1

[0080] This embodiment provides a double-needle bed warp-knitted sandwich mesh fabric containing hot melt wire 3 and its manufacturing method.

[0081] The weaving was performed using a double-needle-bed warp knitting machine, size E24. The yarns used included:

[0082] A: 75D / 36F polyester hot melt yarn FDY;

[0083] B: 300D / 96F recycled polyester lightweight mesh (DTY);

[0084] C: 300D / 10F recycled polyester FDY master yarn.

[0085] Among them, hot melt yarn A is used to form a melt-reinforced structure in an outer layer; body yarn B is used to form the corresponding outer mesh layer; and yarn C is used to form the intermediate connection structure between the first and second layers.

[0086] The structure and feed rate of each comb can be set as follows:

[0087] GB1 hot melt yarn 3 surface layer uses 0-0 / 1-1 / / padding yarn number, A full threading, warp feed is 680mm / rack;

[0088] GB2 surface layer uses 1-0 / 0-1 / / padding yarn number, B full thread, and the warp feed is 2600mm / rack;

[0089] GB3 intermediate layer uses 0-1 / 0-1 / 1-0 / 1-0 / / padding yarn number, C full thread, and the warp feed is 5600mm / rack;

[0090] JB4.1 uses the padding yarn number 1-2 / 1-1 / 1-0 / 1-1 / / , adopts the 1B1* warp threading method, and the warp feed is 2950mm / rack;

[0091] JB4.2 uses the 1-0 / 1-1 / 1-2 / 1-1 / / padding number and the 1B1* warp threading method, with a warp feed of 2950mm / rack.

[0092] GB5 uses a 5-4 / 0-1 / 3-2 / 0-1 / / padding yarn code for the bottom layer, and adopts the 1B1* warp threading method with a warp feed rate of 3200mm / rack;

[0093] GB6 uses a 0-1 / 3-2 / / padding number for the bottom layer, and adopts the 1B1* warp threading method with a warp feed of 2700mm / rack.

[0094] In GB1, the hot melt wire 3 forms a weft-lining structure on the corresponding needle bed through a 0-0 / 1-1 / / weave.

[0095] The hot melt wire 3 coil works in conjunction with the body yarn 1 coil in the mesh layer.

[0096] After weaving is completed, heat setting is performed, which melts the hot melt wire 3 in GB1. Since the hot melt wire 3 was originally located near the coil area of ​​the corresponding weave layer, the molten hot melt material adheres to the coil post and coil arc and spreads along its curved contour.

[0097] In this double-needle bed warp-knitted structure, the loop posts and loop arcs forming the outer layers face the outer surface of the fabric, while the extension yarns and the connecting yarns 2 forming the intermediate layer are located between the two outer layers. The molten material mainly forms a cover in the outer loop area of ​​the mesh layer, so that the final molten reinforced structure is located on the side that actually bears the friction.

[0098] In the heat-set and cooled warp-knitted mesh, the molten material solidifies and combines with the corresponding loops and arcs, thereby forming a double-needle bed warp-knitted mesh with a molten-reinforced structure.

[0099] The resulting product has a longitudinal density of 8.7 cpc and a basis weight of 541 g / m². 2 An abrasion resistance test was conducted on one side of the mesh layer, and the result was 480 revolutions.

[0100] The test results show that setting a melt-reinforced structure in the outer loop area of ​​the double-needle bed warp-knitted mesh can significantly improve the abrasion resistance of the corresponding fabric layer.

[0101] Comparative Example 1

[0102] To compare the abrasion resistance of fabrics with and without the hot melt wire 3 forming a fused reinforcement structure, a control fabric without the hot melt wire 3 surface layer was prepared.

[0103] The control fabric was woven on a double-needle sheet jacquard warp knitting machine, size E24.

[0104] The yarns used include:

[0105] A: 300D / 96F recycled polyester lightweight mesh (DTY);

[0106] B: 300D / 10F recycled polyester FDY master yarn.

[0107] The structure and feed rate of each comb are as follows:

[0108] GB2 surface layer uses 1-0 / 0-1 / / , A full thread, and the warp feed is 2610mm / rack;

[0109] GB3 intermediate layer uses 0-1 / 0-1 / 1-0 / 1-0 / / , B full thread, and the warp feed is 5800mm / rack;

[0110] JB4.1 adopts 1-2 / 1-1 / 1-0 / 1-1 / / , uses 1A1* warp threading method, and the warp feed is 2720mm / rack;

[0111] JB4.2 adopts 1-0 / 1-1 / 1-2 / 1-1 / / , uses 1A1* warp threading method, and the warp feed is 2720mm / rack;

[0112] The GB5 bottom layer uses 5-4 / 0-1 / 3-2 / 0-1 / / , adopts 1A1* warp threading method, and the warp feed is 3130mm / rack;

[0113] The GB6 bottom layer uses 0-1 / 3-2 / / , and adopts the 1A1* warp threading method, with a warp feed amount of 2660mm / rack.

[0114] The control fabric does not have the GB1 hot melt wire 3 surface layer as in Example 1. Therefore, after heat setting, the coil columns and coil arcs on the outer surface of the mesh layer do not have a melt-reinforced structure formed by the melting of the hot melt wire 3.

[0115] The obtained control fabric had a warp density of 8.7 cpc and a weight of 520 g / m². 2 The corresponding mesh layer was subjected to an abrasion resistance test, and the test result was 100 revolutions.

[0116] Compared to the control fabric's 100 revolutions, the abrasion resistance test result of Example 1, which incorporated hot-melt yarn 3 and formed a fused reinforcement structure in the outer loop area, reached 480 revolutions. These test results demonstrate that by weaving hot-melt yarn 3 into the outer layer of a double-needle-bed warp-knitted mesh and using heat setting to cover the loop posts and loop arcs with the hot-melt material, the abrasion resistance of the corresponding layer can be significantly improved.

[0117] Example 2

[0118] This embodiment provides another melt-reinforced double needle bed warp-knitted mesh fabric.

[0119] A first and second fabric layer are formed by using a double needle bed warp knitting machine. The first and second fabric layers are connected by a connecting yarn 2, so that an intermediate layer with a predetermined thickness is formed between the two fabric layers.

[0120] The first layer is a mesh fabric layer with multiple mesh openings, and the second layer can be formed into a mesh fabric structure or other warp-knitted structures depending on the purpose of the fabric.

[0121] During the weaving process of the first layer, the hot melt wire 3 is used through an independent hot melt wire 3 comb, so that the hot melt wire 3 is only placed in the first layer and not in the second layer.

[0122] The weft yarn 3 formed by the hot melt yarn is nested with the loops formed by the main yarn 1 of the first weave layer. After weaving is completed, heat setting is performed, during which the hot melt yarn 3 melts and spreads along the loops and arcs on the outer surface of the first weave layer. As the fabric cools, the molten material solidifies, forming a molten reinforcement structure on the outer surface of the first weave layer.

[0123] Since the second layer does not have the hot melt wire 3, the second layer retains its original yarn structure and surface characteristics, while the first layer receives targeted abrasion resistance reinforcement.

[0124] This implementation method is applicable when the two sides of a double-needle bed warp-knitted mesh have different usage requirements. For example, when the first layer is used as an external friction contact surface for a long time, while the second layer mainly faces inward or is used to bond with other materials, only the first layer can be melt-reinforced.

[0125] Therefore, while improving the wear resistance of the specified friction surface, the amount of hot melt wire 3 can be reduced, and unnecessary treatment of another layer that does not require wear resistance reinforcement can be avoided.

[0126] Example 3

[0127] This embodiment provides a melt-reinforced double needle bed warp-knitted mesh fabric.

[0128] The double-needle bed warp-knitted mesh includes a first layer and a second layer arranged opposite to each other, and an intermediate layer located between the first layer and the second layer.

[0129] At least one of the first and second weave layers is a mesh fabric layer with multiple mesh openings. The mesh fabric layer is woven from body yarn 1, which includes multiple loops and extension yarns connecting adjacent loops.

[0130] The loops forming the outer surface of the mesh layer include loop posts and loop arcs, with the loop posts and loop arcs facing the outside of the double needle bed warp-knitted mesh; at least a portion of the extension yarns and the connecting yarns 2 in the intermediate layer are located between the first and second weave layers.

[0131] At least some of the column and / or arc surfaces of the mesh layer are bonded with fused reinforcement structures. The fused reinforcement structures are formed by heat-setting and melting of hot melt wires 3 pre-woven into the mesh layer during the weaving process, followed by cooling and solidification.

[0132] The fusion-reinforced structure is not an independent film layer formed by coating the already completed double-needle bed warp-knitted mesh, but is formed by melting the hot melt yarn 3, which is pre-woven with the mesh layer body yarn 1, at the original weaving position. Therefore, it can rely on the original structure of the loop column and loop arc to combine with the body yarn 1.

[0133] When the double needle bed warp-knitted mesh is subjected to external friction, the molten reinforcement structure located on the outside of the loop post and loop arc can at least partially bear the friction before the main yarn 1, thereby reducing the direct action of external friction on the main yarn 1 forming the mesh layer and delaying the wear and breakage of the surface loops.

[0134] The above structure can improve the abrasion resistance of at least one outer layer and extend the service life of double needle bed warp knitted mesh while maintaining the original double-layer or three-dimensional structure of double needle bed warp knitted mesh.

[0135] In summary, this application incorporates hot-melt yarns into at least one layer of a double-needle bed warp-knitted mesh, and during heat setting, melts the hot-melt yarns to cover the loop posts and / or loop arcs on the outer surface of the corresponding layer. This allows the hot-melt material to directly act on the loop areas of the double-needle bed warp-knitted mesh that actually bear external friction. Since the loop posts and loop arcs of the double-needle bed warp-knitted mesh mainly face the outer surface of the fabric, while the extension yarns and connecting yarns are mainly located between the first and second layers, the melt-reinforced structure can be matched with the position of the surface loops that are prone to wear. This reduces the direct effect of external friction on the main yarn, lowers the possibility of loop fuzzing, wear, and breakage, thereby improving the abrasion resistance and overall service life of the mesh layer.

[0136] Simultaneously, the hot melt yarn directly participates in the weaving of the corresponding layer during the weaving process. Through independent hot melt yarn combs, the hot melt yarn coils come into contact with the main yarn coils, allowing the hot melt yarn to be stably held in the coil area to be reinforced before heat setting. This facilitates its spread along the curved contours of the loops and arcs after melting, forming a stable, solidified covering structure and improving the bonding stability between the molten material and the original coil structure. Furthermore, hot melt yarn can be placed only in the first or second layer to specifically reinforce the side of the double-needle bed warp-knitted mesh where abrasion resistance is low or where friction is primarily experienced. This improves the abrasion resistance of that side while reducing unnecessary hot melt yarn usage and minimizing the impact on the original softness, breathability, and surface properties of the other layer, thereby enhancing the practicality and applicability of the double-needle bed warp-knitted mesh.

[0137] 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 method for manufacturing a melt-reinforced double-needle-bed warp-knitted mesh, characterized in that, include: A first and second woven layers are formed by knitting with a double needle bed warp knitting machine, and hot melt yarn is woven into at least one woven layer to form a warp-knitted mesh fabric. The warp-knitted mesh fabric is heat-set to melt the hot melt wires and cover the coil columns and / or coil arcs on the outer surface of the corresponding weave layer, forming a melt-reinforced structure. In the warp-knitted mesh fabric that has been cooled after heat setting, the melt-reinforced structure solidifies to obtain a melt-reinforced double-needle bed warp-knitted mesh fabric.

2. The method for manufacturing the melt-reinforced double-needle bed warp-knitted mesh according to claim 1, characterized in that, A connecting yarn is woven between the first fabric layer and the second fabric layer, the connecting yarn connecting the first fabric layer and the second fabric layer, and forming an intermediate layer between them; At least one of the first and second fabric layers is a mesh fabric layer with multiple mesh openings, and the outer surface of the mesh fabric layer is composed of multiple loops woven from corresponding needle beds.

3. The method for manufacturing the melt-reinforced double-needle-bed warp-knitted mesh according to claim 2, characterized in that, The body yarn forming the mesh layer includes loops and extension lines connecting adjacent loops, with the loop posts and loop arcs facing the outer surface of the mesh layer, and the extension lines facing between the first weave layer and the second weave layer.

4. The method for manufacturing the melt-reinforced double-needle bed warp-knitted mesh according to claim 3, characterized in that, The hot melt yarn is woven using a hot melt yarn comb independent of the main yarn comb, so that the hot melt yarn is evenly distributed in the loops formed by the main yarn in the mesh layer.

5. The method for manufacturing the melt-reinforced double-needle bed warp-knitted mesh according to claim 3, characterized in that, After heat setting, the molten hot-melt wire is attached between the coil post and the coil arc, and covers at least a portion of the surface of the coil post and the coil arc, so that the molten reinforcement structure is located on the side of the mesh layer that is subjected to external friction.

6. The method for manufacturing the melt-reinforced double-needle-bed warp-knitted mesh according to claim 5, characterized in that, During the heat setting process, the molten hot melt wire spreads along the curved contours of the cylinder and the arc, and after cooling, forms a solidified covering structure that is bonded to the cylinder and the arc.

7. The method for manufacturing the melt-reinforced double-needle bed warp-knitted mesh according to claim 1, characterized in that, The hot melt yarn is woven into the first or second layer, so that the melt-reinforced structure is formed on one side of the double needle bed warp-knitted mesh.

8. A melt-reinforced double-needle-bed warp-knitted mesh fabric, characterized in that, The fabric is manufactured using the manufacturing method of the melt-reinforced double needle bed warp-knitted mesh as described in any one of claims 1-7.

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