Elastic air layer fabric with air-permeable sweat-absorbing and quick-drying functions and preparation method thereof

Abstract

The application discloses an elastic air layer fabric with air-permeable sweat-releasing, moisture-absorbing and quick-drying functions and a preparation method thereof, and relates to the technical field of textile fabrics.The elastic air layer fabric with air-permeable sweat-releasing, moisture-absorbing and quick-drying functions comprises a double-layer air layer structure formed by weft knitting double-face organization;the elastic air layer fabric with air-permeable sweat-releasing, moisture-absorbing and quick-drying functions and the preparation method thereof are characterized in that: the modal fiber yarn and the cross-section moisture-absorbing and quick-drying polyester fiber yarn are alternately and uniformly arranged in the weft direction at one interval, the spandex elastic filament is simultaneously fed and embedded between the surface layer and the bottom layer of the double-layer air layer structure, and the natural moisture-absorbing property of the modal fiber and the capillary wet-conducting effect of the surface groove of the cross-section polyester fiber are synergistically combined, sweat can be quickly absorbed and rapidly diffused and conducted along the fiber axial groove to the outer layer of the fabric for evaporation, the two contradictory properties of moisture absorption and quick drying are unified in the same fabric, and the quick-drying function is derived from the cross-section structure of the fiber itself instead of post-finishing additives, and the function does not decrease due to washing.

Description

Technical Field

[0001] This invention relates to the field of textile fabric technology, specifically to an elastic air layer fabric with breathable, sweat-wicking, moisture-absorbing, and quick-drying functions and its preparation method. Background Technology

[0002] The research and application of functional moisture-wicking and quick-drying fabrics has undergone many years of development. Early moisture-wicking and quick-drying fabrics mainly used single-fiber raw materials, such as pure cotton or ordinary polyester, but a single fiber cannot simultaneously achieve both moisture-wicking and quick-drying properties. Subsequently, the industry commonly adopted blending or interweaving of natural and synthetic fibers, attempting to achieve functional complementarity through raw material compounding. However, due to the fundamental differences between natural fibers (such as cotton and modal) and synthetic fibers (such as polyester and nylon) in surface chemical properties, moisture adsorption-desorption behavior, and wettability, they often form independent moisture management pathways within the same fabric, lacking effective functional synergy. Furthermore, to compensate for the insufficient hydrophilicity of synthetic fibers, many commercially available products use hydrophilic finishing agents to coat and modify the fabric; however, these agents lack strong chemical bonding with the fiber matrix and are difficult to withstand repeated washing. Therefore, how to achieve synergistic enhancement of moisture wicking and quick-drying in the same fabric without the need for finishing agents, and ensure its long-term effectiveness, has been a long-term focus in this field.

[0003] In existing technologies, when hygroscopic fibers are blended or interwoven with quick-drying fibers, the moisture absorbed by the hygroscopic fibers is difficult to effectively transfer to the surface of the quick-drying fibers and evaporate. Instead, the hygroscopic fibers swell after absorbing water, blocking the moisture-conducting channels between fibers and yarns, thus preventing the migration path of moisture to the quick-drying fibers, resulting in a moisture-retaining effect. The direct consequence of this effect is that although the fabric has a certain moisture-absorbing capacity, the moisture is locked inside the hygroscopic fibers and cannot be discharged and evaporated in time. The overall drying rate is not substantially improved by the presence of quick-drying fibers. The two properties of moisture absorption and quick-drying in the same fabric mutually hinder each other or even cancel each other out, thus requiring improvement. Summary of the Invention

[0004] The purpose of this invention is to provide an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions and its preparation method, so as to solve the problem in the prior art that when moisture-wicking fibers are blended or interwoven with quick-drying fibers, the moisture-wicking fibers absorb water and swell, blocking the moisture-conducting channels between fibers and preventing the migration of moisture to quick-drying fibers.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking and quick-drying functions, comprising a double-layer air layer structure formed by a weft-knitted double-sided structure, wherein the fabric is woven from a weft yarn system, and the weft yarn system is composed of a first yarn, a second yarn and a third yarn;

[0006] The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn;

[0007] The first yarn and the second yarn are arranged in a uniform, alternating pattern in the weft direction to participate in weaving to form the surface layer and the bottom layer of the double-layer air layer structure. The third yarn is simultaneously fed in and embedded between the surface layer and the bottom layer during the weaving process.

[0008] Furthermore, the cross-section of the moisture-wicking and quick-drying polyester fiber yarn has a cross-shaped cross-section, and multiple continuous grooves are formed on the surface of each fiber along the axial direction.

[0009] Furthermore, the ratio of the number of the first yarn to the number of the second yarn in the weft direction is 1:1.

[0010] Furthermore, the double-layer air layer structure is specifically a weft-knitted rib air layer structure.

[0011] Furthermore, the third yarn extends and embeds itself continuously in the fabric in both the transverse and longitudinal directions.

[0012] Furthermore, the top layer and the bottom layer are separated by connecting yarns to form a closed air gap.

[0013] A method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-absorbing, and quick-drying functions includes the following steps:

[0014] S1. Prepare modal fiber yarn as the first yarn, prepare cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, and prepare spandex elastic yarn as the third yarn.

[0015] S2. Weft knitting double-sided circular knitting machine is used for knitting. The first yarn and the second yarn are fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating and uniform manner in the weft direction. At the same time, the third yarn is fed into the knitting area so that the third yarn is sandwiched between the upper and lower layers of the fabric during the looping process.

[0016] S3. A fabric with a double-layer air layer structure is formed by double-sided weaving process, in which the first yarn and the second yarn are interwoven to form a surface layer and a bottom layer, and the third yarn is embedded between the surface layer and the bottom layer in a sandwich state.

[0017] S4. Perform finishing treatment on the woven fabric to obtain the elastic air layer fabric.

[0018] Furthermore, the weft knitting double-sided circular knitting machine is a weft knitting rib double-sided circular knitting machine, and the double-sided knitting process is a rib air layer knitting process.

[0019] Furthermore, the finishing process includes a shaping process, a dyeing process, and a drying process performed sequentially.

[0020] Compared with existing technologies, the present invention provides an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions and its preparation method. Modal fiber yarn and cross-section moisture-wicking and quick-drying polyester fiber yarn are evenly arranged in the weft direction with alternating layers. Spandex elastic yarn is simultaneously fed in and embedded between the top and bottom layers of the double-layer air layer structure. This allows the natural moisture absorption of modal fiber and the capillary moisture-wicking effect of the grooves on the surface of cross-section polyester fiber to work synergistically. Sweat can be quickly absorbed and rapidly diffused and conducted along the fiber axial grooves to the outer layer of the fabric for evaporation. The two contradictory properties of moisture absorption and quick-drying are unified in the same fabric. Moreover, the quick-drying function comes from the cross-sectional structure of the fiber itself rather than finishing agents, and the function is not diminished by washing.

[0021] The cross-section moisture-wicking and quick-drying polyester fibers have a high wet yield modulus. Combined with the weft-knitted rib air layer structure that forms an air gap between the top and bottom layers, the fabric fibers do not easily collapse after absorbing moisture. The top and bottom layers remain separated in a wet state, thus maintaining a microclimate space between the fabric and the skin, effectively eliminating the sticky feeling when wet. At the same time, the air gap remains stable during wear, taking into account both breathability and moisture wicking when sweat evaporates and heat retention when at rest.

[0022] The fabric structure is formed by weft-knitted rib air layer weaving three loop systems to create an overall structure of top layer, bottom layer and air layer between them. Combined with the 1:1 alternating and uniform arrangement of modal fiber yarn and cross-section moisture-wicking and quick-drying polyester fiber yarn, and the embedded spandex elastic yarn, the fabric structure is formed in one step during the weaving process. The top layer and bottom layer are fixedly connected by connecting loops without additional bonding process, avoiding the interlayer slippage and bubbling problems common in multi-layer composite fabrics. At the same time, the spandex elastic yarn extends continuously in both the horizontal and vertical directions in the top and bottom layers to form an elastic network, giving the fabric lasting dimensional stability and resilience. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0024] Figure 1 The preparation process flowchart is provided for an embodiment of the present invention. Detailed Implementation

[0025] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0026] As attached Figure 1 As shown:

[0027] Example 1:

[0028] This invention provides an elastic air-layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions. In this embodiment, the fabric is a weft-knitted fabric, woven using a double-sided circular knitting machine to form a double-layer air-layer structure. The fabric is woven from a weft yarn system, which consists of a first yarn, a second yarn, and a third yarn. The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn.

[0029] The first yarn, Modal fiber yarn, is spun from Lenzing Modal fiber with a count of 40S (metric count) using a Siro compact spinning process. The second yarn, cross-section moisture-wicking and quick-drying polyester fiber yarn, is processed from polyester filaments spun using a cross-section spinneret. The fiber cross-section is cross-shaped, and the fiber surface has four continuous grooves along the axial direction. This second yarn is a 75D / 72F (75 denier, 72 monofilaments) textured yarn (DTY). The third yarn, spandex elastic yarn, is made from polyurethane elastic fiber with a fineness of 30D.

[0030] The first and second yarns are evenly arranged in the weft direction, alternating every other yarn. Specifically, during the weft-weft process, the first and second yarns are fed into the weft-weft area alternately in a 1:1 ratio. The ratio of the number of first and second yarns in the weft direction is 1:1.

[0031] The fabric employs a weft-knitted rib air-layer structure. This structure is completed by three loop-forming systems. The first loop-forming system participates in knitting on both purl and knit needles, forming a 1+1 rib cross row; the second loop-forming system knits only on purl (or knit) needles, with needles on the other needle bed forming floats; the third loop-forming system knits on needles on the other needle bed, with needles on the previous needle bed forming floats. Through the coordination of these three loop-forming systems, an air layer is formed between the upper (outer) and lower (bottom) layers of the fabric. During the knitting process, a third yarn, spandex elastic yarn, is simultaneously fed into the knitting area, held between the upper and bottom layers during loop formation, and embedded in the double-layer air-layer structure in an air-layer state. The spandex elastic yarn extends continuously and embeds itself in the fabric along both the transverse and longitudinal directions.

[0032] The finished weight of the fabric is 280g / m² to 320g / m². The finished width of the fabric is 150cm to 160cm.

[0033] The fabric preparation method in this embodiment is as follows:

[0034] Prepare the yarns: Prepare the above-mentioned modal fiber yarn as the first yarn, with a yarn count of 40S; prepare the above-mentioned cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, with a specification of 75D / 72F DTY; prepare the above-mentioned spandex elastic yarn as the third yarn, with a fineness of 30D.

[0035] Knitting: A weft-knitting double-sided circular knitting machine is used, specifically a weft-knitting rib double-sided circular knitting machine. The first and second yarns are fed into the upper and lower needle cylinders of the knitting area in an alternating, evenly spaced pattern in the weft direction. The knitting process employs a rib air-layer knitting technique, with three loop-forming systems completing a full structure. In the first loop-forming system, both the purl and knit needles participate in the knitting, forming a 1+1 rib pattern; the second loop-forming system knits only on the knit needles; and the third loop-forming system knits only on the purl needles. During the knitting process, the third yarn, spandex elastic yarn, is simultaneously fed into the knitting area, where it is held between the surface and underlayer layers of the fabric during loop formation. The knitting equipment is a 12-needle / 25.4mm (i.e., 12 needles / inch) weft-knitting double-sided circular knitting machine. During the knitting process, the yarn tension is controlled at 3cN to 5cN, the pull force at 20N to 30N, and the yarn bending depth at 2.5mm to 3.5mm. The above weaving process forms a fabric with a double-layer air layer structure, in which the first yarn and the second yarn are interwoven to form the surface layer and the bottom layer, and the third yarn is embedded between the surface layer and the bottom layer in a sandwich state.

[0036] Finishing: The woven fabric undergoes finishing treatment. This includes sequential setting, dyeing, and drying. Setting is performed on a setting machine at a temperature of 150℃ to 180℃. Dyeing is carried out in a high-temperature, high-pressure dyeing machine at a temperature of 120℃ to 130℃ for 30 to 45 minutes. Drying is performed in a dryer at a temperature of 100℃ to 120℃. After finishing, the finished elastic air-layer fabric is obtained.

[0037] Example 2:

[0038] In this embodiment, the fabric is a weft-knitted fabric, woven using a double-sided circular knitting machine to form a double-layer air-layer structure. The fabric is woven from a weft yarn system, which consists of a first yarn, a second yarn, and a third yarn. The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn.

[0039] The first yarn is made of Lenzing Modal fiber, with a yarn count of 50S (metric count), and is spun using the Siro compact spinning process.

[0040] The second yarn, a cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. The cross-section of a single fiber in this second yarn is cross-shaped. Specifically, the cross-section of the fiber has four symmetrically distributed protrusions extending in two mutually perpendicular directions, forming four continuous grooves extending along the fiber axis between adjacent protrusions. The groove depth is 15% to 25% of the fiber's equivalent diameter. The groove width is 20% to 35% of the fiber's equivalent diameter. This second yarn is a 150D / 144F (i.e., 150 denier, 144 monofilaments) textured yarn (DTY).

[0041] The third yarn, spandex elastic yarn, is made of polyurethane elastic fiber with a fineness of 40D.

[0042] The first and second yarns are knitted in a uniform, alternating pattern in the weft direction. The ratio of the number of first and second yarns in the weft direction is 1:1.

[0043] The fabric employs a weft-knitted rib air-layer structure. This structure is completed by three loop-forming systems. The first loop-forming system participates in knitting on both purl and knit needles, forming a 1+1 rib cross row; the second loop-forming system knits only on knit needles, with purl needles forming floats; the third loop-forming system knits only on purl needles, with knit needles forming floats. Through the coordination of these three loop-forming systems, an air layer is formed between the top and bottom layers of the fabric. During the knitting process, a third yarn, spandex elastic yarn, is simultaneously fed into the knitting area, held between the top and bottom layers during loop formation, and embedded in the double-layer air-layer structure in an air-layer state. The spandex elastic yarn extends continuously and embeds itself in the fabric along both the transverse and longitudinal directions.

[0044] The finished weight of the fabric is 180g / m² to 220g / m². The finished width of the fabric is 150cm to 160cm.

[0045] The fabric preparation method in this embodiment is as follows:

[0046] Prepare the yarns: Prepare the above-mentioned modal fiber yarn as the first yarn, with a yarn count of 50S; prepare the above-mentioned cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, with a specification of 150D / 144F DTY; prepare the above-mentioned spandex elastic yarn as the third yarn, with a fineness of 40D.

[0047] Knitting: A weft-knitting double-sided circular knitting machine is used, specifically a weft-knitting rib double-sided circular knitting machine. The first and second yarns are fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating, evenly spaced pattern in the weft direction. The knitting process employs a rib air-layer knitting technique, with three loop-forming systems completing a full structure. In the first loop-forming system, both the purl and knit needles participate in the knitting, forming a 1+1 rib pattern; in the second loop-forming system, only the knit needles knit, with the purl needles forming floats; and in the third loop-forming system, only the purl needles knit, with the knit needles forming floats. During the knitting process, the third yarn, spandex elastic yarn, is simultaneously fed into the knitting area, where it is held between the surface and underlayer layers of the fabric during loop formation. The knitting equipment used is a 14-needle / 25.4mm (i.e., 14 needles / inch) weft-knitting double-sided circular knitting machine. During the weaving process, the yarn tension is controlled at 2.5cN to 4cN, the pulling force at 18N to 25N, and the yarn bending depth at 2.2mm to 3.0mm. This weaving process forms a fabric with a double-layer air-layer structure, where the first and second yarns interweave to form the surface and bottom layers, and the third yarn is embedded between the surface and bottom layers in a sandwich state.

[0048] Finishing: The woven fabric undergoes finishing treatment. This includes sequential setting, dyeing, and drying. Setting is performed on a setting machine at a temperature of 150℃ to 180℃. Dyeing is carried out in a high-temperature, high-pressure dyeing machine at a temperature of 120℃ to 130℃ for 30 to 45 minutes. Drying is performed in a dryer at a temperature of 100℃ to 120℃. After finishing, the finished elastic air-layer fabric is obtained.

[0049] Example 3:

[0050] In this embodiment, the fabric is a weft-knitted fabric, woven using a double-sided circular knitting machine to form a double-layer air-layer structure. The fabric is woven from a weft yarn system, which consists of a first yarn, a second yarn, and a third yarn. The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn.

[0051] The first yarn is made of Lenzing Modal fiber, with a yarn count of 32S (metric count), spun using the Siro compact spinning process, and a yarn twist of 850 twists per meter.

[0052] The second yarn, a cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. Each fiber in the second yarn has a cross-shaped cross-section, and four continuous grooves are formed along the axial direction on the fiber surface. This second yarn is a 100D / 96F (100 denier, 96 filaments) textured yarn with a breaking strength of 3.8 cN / dtex to 4.2 cN / dtex and a breaking elongation of 25% to 30%.

[0053] The third yarn, spandex elastic yarn, is made of polyurethane elastic fiber with a fineness of 20D and a breaking elongation of 400% to 500%.

[0054] The first and second yarns participate in the weft weaving process by alternating evenly spaced yarns. Specifically, during the weft feeding process, the first and second yarns are fed into the same weft system in a 1:1 ratio. That is, in each weft, the first and second yarns alternate, with the first yarn occupying weft positions 1, 3, 5, 7... and the second yarn occupying weft positions 2, 4, 6, 8... The ratio of the number of first and second yarns in the weft direction is 1:1. The third yarn, spandex elastic yarn, is fed in parallel with either the first or second yarn in each weft.

[0055] The fabric employs a weft-knitted rib air-layer structure. This structure is completed by three loop-forming systems. The first loop-forming system involves all knitting needles, forming a 1+1 rib row; the second loop-forming system only knits on the knit needles, with the knit needles forming floats; the third loop-forming system only knits on the knit needles, with the knit needles forming floats. After the first loop-forming system is knitted, the knit and purl stitches of the fabric alternate horizontally and interlock, forming the starting rows of the top and bottom layers. When the second loop-forming system is knitted on the knit needles alone, only the bottom layer adds one loop row, with the top layer yarn floating across this row. When the third loop-forming system is knitted on the knit needles alone, only the top layer adds one loop row, with the bottom layer yarn floating across this row. Through the cyclical coordination of these three loop-forming systems, an air layer is formed between the top and bottom layers of the fabric. The thickness of the air layer is determined by the length of the connecting yarn between the top and bottom layers.

[0056] During the weaving process, the third yarn, spandex elastic yarn, is simultaneously fed into the weaving area of ​​each loop-forming system using a constant tension and active unwinding method. The spandex elastic yarn is sandwiched between the top and bottom layers during loop formation, embedded in the double-layer air-layer structure in a sandwich state. The spandex elastic yarn extends continuously and embeds itself in the fabric in the transverse direction, while simultaneously extending and embedding itself in a wavy pattern in the longitudinal direction as the loops bend and form. The content of spandex elastic yarn in the fabric is 3% to 8% of the total fabric mass.

[0057] The top and bottom layers are connected by connecting loops formed when the purl and knit needles are knitted simultaneously in the first looping system. Except for the location of the connecting loops, the top and bottom layers are separated, forming a closed air gap.

[0058] The finished weight of the fabric is 300g / m² to 340g / m². The finished width of the fabric is 155cm to 165cm. The warp density of the fabric is 50 to 60 stitches per 5cm, and the weft density is 70 to 80 stitches per 5cm.

[0059] The fabric preparation method in this embodiment is as follows:

[0060] Prepare the yarns: Prepare the above-mentioned modal fiber yarn as the first yarn, with a yarn count of 32S and a twist of 850 twists per meter; prepare the above-mentioned cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, with a specification of 100D / 96F DTY; prepare the above-mentioned spandex elastic yarn as the third yarn, with a fineness of 20D.

[0061] Knitting: A weft-knitting double-sided circular knitting machine is used. This machine is a weft-knitting rib double-sided circular knitting machine with a cylinder diameter of 762mm (30 inches) and a needle count of 14 needles / 25.4mm. The first and second yarns are fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating, evenly spaced pattern in the weft direction. An active feeding method is used, with the feeding tension of the first and second yarns controlled separately by a weft feeder. The knitting process employs a rib air-layer knitting technique, with three loop-forming systems completing one complete structure. In the first loop-forming system, all purl and knit needles participate in the knitting, forming a 1+1 rib cross; in the second loop-forming system, only knitting on the knit needles, with the purl needles forming floats; and in the third loop-forming system, only knitting on the purl needles, with the knit needles forming floats. During the weaving process, a third yarn, spandex elastic filament, is simultaneously fed into the weaving area at constant tension using an active unwinding method. Guided by a yarn guide, the spandex elastic filament is fed parallel to the first or second yarn into the same knitting needle, where it is held between the surface and bottom layers of the fabric during loop formation. During weaving, the yarn tension is controlled at 3cN to 4.5cN, the pull force at 22N to 28N, the bending depth at 2.8mm to 3.2mm, and the machine speed at 18 to 22 revolutions per minute. This weaving process creates a fabric with a double-layer air-layer structure, where the first and second yarns interweave to form the surface and bottom layers, while the third yarn is embedded between them in a sandwich-like state.

[0062] Post-finishing: The woven fabric undergoes post-finishing treatment. This includes sequential setting, dyeing, and drying. Setting is performed on a setting machine at a temperature of 160℃ to 175℃ and a setting speed of 25m to 35m per minute. Dyeing is carried out in a high-temperature, high-pressure dyeing machine with a dyeing liquor ratio of 1:10 to 1:12, a dyeing temperature of 125℃ to 130℃, a heating rate of 1.0℃ to 1.5℃ per minute, a holding time of 35 to 40 minutes, and a cooling rate of 1.0℃ to 1.5℃ per minute. Drying is performed in a dryer at a temperature of 105℃ to 115℃ and a drying time of 3 to 5 minutes. After post-finishing, the finished elastic air-layer fabric is obtained.

[0063] Example 4:

[0064] In this embodiment, the fabric is a weft-knitted fabric, woven using a double-sided circular knitting machine to form a double-layer air-layer structure. The fabric is woven from a weft yarn system, which consists of a first yarn, a second yarn, and a third yarn. The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn.

[0065] The first yarn, Modal fiber yarn, is spun from Lenzing Modal fiber with a yarn count of 40S (metric count) and is produced using the Siro compact spinning process.

[0066] The second yarn, a cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. Each fiber in this second yarn has a cross-shaped cross-section, and four continuous grooves are formed along the axial direction on the fiber surface. This second yarn is a 75D / 72F (i.e., 75 denier, 72 filaments) textured yarn.

[0067] The third yarn, spandex elastic yarn, is made of polyurethane elastic fiber with a fineness of 30D.

[0068] The first and second yarns are knitted in a uniform, alternating pattern in the weft direction. The ratio of the number of first and second yarns in the weft direction is 1:1.

[0069] The fabric employs a weft-knitted rib air-layer structure. This structure is completed by three loop-forming systems. The first loop-forming system involves all knitting needles, meaning both the knitting needles in the knitting die and the purl needles in the purl cylinder are knitted in loops, forming a 1+1 rib pattern. The second loop-forming system involves only purl needles; the knitting needles do not participate, and no yarn is fed into the knitting needle hooks, leaving the knitting needles in a floating state relative to the cylinder. The third loop-forming system involves only knitting needles; the purl needles do not participate, and no yarn is fed into the purl needle hooks, leaving the purl needles in a floating state relative to the cylinder.

[0070] In the three loop-forming systems described above, during the knitting of the first loop-forming system, the first and second yarns are fed simultaneously into the purl and knit needles in an alternating manner. Specifically, in the first loop-forming system, the first needle (purl or knit) feeds the first yarn, the second needle feeds the second yarn, the third needle feeds the first yarn, the fourth needle feeds the second yarn, and so on, with the first and second yarns being fed alternately around the circumference of the needle cylinder. After the first loop-forming system is completed, the top and bottom layers of the fabric simultaneously form the starting row, which is connected to each other by interlocking loops. During the knitting of the second loop-forming system, only the knit needles participate in the knitting. The first or second yarn is fed into the knit needle hook in an alternating manner, while the purl needles do not participate in the knitting. Therefore, this loop-forming system only forms a new row of loops on the bottom layer, and the yarn at the corresponding position on the top layer floats between adjacent needles. When knitting the third loop-forming system, only the purl needles participate in the knitting. The first or second yarn is fed into the purl needle hook in an alternating pattern, while the knitting needles do not participate. Therefore, this loop-forming system only forms new loop rows on the surface layer, while the yarn at the corresponding position on the bottom layer floats across the spaces between adjacent needles. The second and third loop-forming systems are knitted in a sequential cycle, causing the surface and bottom layers to increase loop rows while creating an air gap between them due to the presence of the float yarn. The length of the float yarn is equal to the stitch length between two adjacent working needles, which is determined by the knitting machine size.

[0071] In the second loop-forming system, the bottom layer loops formed after the down stitch completes the loop formation are interlocked with the bottom layer starting row loops already formed in the first loop-forming system. In the third loop-forming system, the top layer loops formed after the up stitch completes the loop formation are interlocked with the top layer starting row loops already formed in the first loop-forming system. The top and bottom layers are fixed together by connecting loops formed in the first loop-forming system. No connection points are created between the top and bottom layers in the second and third loop-forming systems; therefore, the top and bottom layers remain separated in the fabric cross-section outside the connecting loop locations.

[0072] During the knitting process, a third yarn, spandex elastic yarn, is simultaneously fed into the knitting area of ​​each loop-forming system. The spandex elastic yarn is fed parallel to the first or second yarn into the hook of the same needle and is held by the loops during loop formation. In the first loop-forming system, the spandex elastic yarn is embedded into the rib loops of the top and bottom layers respectively with the loop formation of the purl and knit needles. In the second loop-forming system, the spandex elastic yarn is embedded into the bottom layer loops with the purl needles, while simultaneously slack across the needles in the floats of the top layer. In the third loop-forming system, the spandex elastic yarn is embedded into the top layer loops with the purl needles, while simultaneously slack across the needles in the floats of the bottom layer. The spandex elastic yarn extends continuously and embeds itself in the fabric along both the transverse and longitudinal directions.

[0073] The finished weight of the fabric is 260g / m² to 300g / m². The finished width of the fabric is 150cm to 160cm.

[0074] The fabric preparation method in this embodiment is as follows:

[0075] Prepare the yarns: Prepare the above-mentioned modal fiber yarn as the first yarn, with a yarn count of 40S; prepare the above-mentioned cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, with a specification of 75D / 72F DTY; prepare the above-mentioned spandex elastic yarn as the third yarn, with a fineness of 30D.

[0076] Knitting: A weft-knitting double-sided circular knitting machine is used, specifically a weft-knitting rib double-sided circular knitting machine. The first and second yarns are fed into the upper and lower needle cylinders of the knitting area in an alternating, even arrangement in the weft direction. The knitting process employs a rib air-layer knitting technique, with three loop-forming systems completing a full structure. In the first loop-forming system, all purl and knit needles participate in the knitting, forming a 1+1 rib cross; in the second loop-forming system, only knit needles participate, with purl needles forming floats; in the third loop-forming system, only purl needles participate, with knit needles forming floats. The three loop-forming systems operate in a cyclical manner, following the sequence of the first, second, and third loop-forming systems. Within each loop-forming system, the first and second yarns are fed into the knitting needles in an alternating, alternating manner. During the knitting process, the third yarn, spandex elastic yarn, is simultaneously fed into the knitting area of ​​each loop-forming system in a parallel manner, allowing the spandex elastic yarn to be held within the surface and bottom loops of the fabric during loop formation. The knitting equipment is a 12-needle / 25.4mm (i.e., 12 needles / inch) weft-knitted double-sided circular knitting machine. During the knitting process, the yarn tension is controlled at 3cN to 5cN, the pull force at 20N to 30N, and the yarn bending depth at 2.5mm to 3.5mm. This knitting process forms a fabric with a double-layer air-layer structure, where the first and second yarns interweave to form the face layer and the back layer, and the third yarn is embedded between the face layer and the back layer in a sandwich state. The face layer and the back layer are connected by connecting loops formed in the first loop-forming system. In the areas formed by the second and third loop-forming systems, the face layer and the back layer separate to form an air-layer.

[0077] Finishing: The woven fabric undergoes finishing treatment. This includes sequential setting, dyeing, and drying. Setting is performed on a setting machine at a temperature of 150℃ to 180℃. Dyeing is carried out in a high-temperature, high-pressure dyeing machine at a temperature of 120℃ to 130℃ for 30 to 45 minutes. Drying is performed in a dryer at a temperature of 100℃ to 120℃. After finishing, the finished elastic air-layer fabric is obtained.

[0078] Example 5:

[0079] In this embodiment, the fabric is a weft-knitted fabric, woven using a double-sided circular knitting machine to form a double-layer air-layer structure. The fabric is woven from a weft yarn system, which consists of a first yarn, a second yarn, and a third yarn. The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn.

[0080] The first yarn is made of Lenzing Modal fiber, with a yarn count of 40S (metric count), and is spun using the Siro compact spinning process. The single yarn breaking strength is 22cN / tex to 26cN / tex.

[0081] The second yarn, a cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. Each fiber in the second yarn has a cross-shaped cross-section, and four continuous grooves are formed along the axial direction on the fiber surface. This second yarn is a 75D / 72F (i.e., 75 denier, 72 filaments) textured yarn.

[0082] The third yarn, spandex elastic yarn, is made of polyurethane elastic fiber with a fineness of 30D.

[0083] The first and second yarns are knitted in a uniform, alternating pattern in the weft direction. The ratio of the number of first and second yarns in the weft direction is 1:1.

[0084] The fabric employs a weft-knitted rib air layer structure. This structure is completed by three loop-forming systems. The first loop-forming system involves all knit and purl needles, forming a 1+1 rib row. The second loop-forming system involves only purl needles, with knit needles forming floats. The third loop-forming system involves only purl needles, with purl needles forming floats. Through the cyclical coordination of these three loop-forming systems, an air layer is formed between the surface and underlayer of the fabric.

[0085] The third yarn, spandex elastic filament, is simultaneously fed into the knitting area of ​​each loop-forming system during the knitting process. Guided by a yarn guide, the spandex elastic filament is fed parallel to the first or second yarn into the hook of the same knitting needle. In each loop-forming system, the spandex elastic filament is fed in beside the first or second yarn, and all three yarns (i.e., the first yarn and the spandex elastic filament, or the second yarn and the spandex elastic filament) enter the needle hook together, where they are simultaneously bent into loops as the needle descends and bends.

[0086] During the knitting of the first loop system, spandex elastic yarn is fed into the knitting needles along with the first and second yarns. When the knitting needles simultaneously form loops, the spandex elastic yarn bends together with the first or second yarn in the knitting needles to form the surface loops, and in the knitting needles, it bends together with the first or second yarn to form the bottom loops. In this loop system, the spandex elastic yarn forms continuous rows of loops, connecting adjacent needles in the transverse direction. Simultaneously, each loop interlocks with the loops of the previous row in the longitudinal direction, thus achieving continuous extension of the spandex elastic yarn in both the transverse and longitudinal directions of the fabric.

[0087] During the second loop-forming system, the spandex elastic yarn is fed into the needle hook along with the first or second yarn. The needle completes the loop-forming process, while the purl needle does not participate in the knitting. The spandex elastic yarn, together with the first or second yarn, bends in the needle to form the bottom layer loop. This bottom layer loop interlocks with the bottom layer loops already formed in the first loop-forming system along the longitudinal direction. Simultaneously, the spandex elastic yarn does not form a loop at the corresponding position on the surface layer, but instead crosses the row as a float. This float crosses the stitch length between adjacent needles in the transverse direction and is fixed by the surface layer loops in subsequent loop-forming systems.

[0088] When knitting the third loop system, the spandex elastic yarn is fed into the hook of the upper needle along with the first or second yarn. The upper needle completes the loop knitting, while the lower needle does not participate in the knitting. The spandex elastic yarn, together with the first or second yarn, bends in the upper needle to form the surface layer loop. This surface layer loop interlocks with the surface layer loops already formed in the first loop system along the longitudinal direction. At the same time, the spandex elastic yarn does not form a loop at the corresponding position in the bottom layer, but instead crosses the row as a floating yarn.

[0089] After being woven through three loop systems, the spandex elastic yarns form a continuous mesh distribution structure in the fabric. In the transverse direction, the spandex elastic yarns connect adjacent needles through loops formed in each loop system, extending continuously across the entire width of the fabric. In the longitudinal direction, the spandex elastic yarns connect each row of loops with the previous row, extending continuously along the entire length of the fabric. The spandex elastic yarns exist simultaneously in the top and bottom layers. The spandex elastic yarns in the top layer extend along the direction of the top layer loops, and the spandex elastic yarns in the bottom layer extend along the direction of the bottom layer loops. There is no direct connection between the spandex elastic yarns in the air gap areas between the top and bottom layers; instead, they are connected at the connecting loop positions through a connecting structure formed by the simultaneous knitting of the up and down needles within the same loop system.

[0090] Spandex elastic yarn is embedded in the fabric as bare yarn without covering. The content of spandex elastic yarn in the fabric is 3% to 6% of the total weight of the fabric. The elongation of the spandex elastic yarn in the fabric is 1.5 to 2.5 times that of the fabric before elongation, that is, the spandex elastic yarn is fed in a stretched state during the weaving process, with a stretch ratio of 1.5 to 2.5.

[0091] The outer and back layers of the fabric are connected by connecting loops formed by the simultaneous knitting of the purl and knitting needles in the first loop-forming system. Except for the locations of the connecting loops, the areas between the outer and back layers are separated to form an air gap. The thickness of the air gap is 0.3 mm to 0.8 mm.

[0092] The finished weight of the fabric is 280g / m² to 320g / m². The finished width of the fabric is 150cm to 160cm.

[0093] The fabric preparation method in this embodiment is as follows:

[0094] Prepare the yarns: Prepare the above-mentioned modal fiber yarn as the first yarn, with a yarn count of 40S; prepare the above-mentioned cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, with a specification of 75D / 72F DTY; prepare the above-mentioned spandex elastic yarn as the third yarn, with a fineness of 30D.

[0095] Knitting: A weft-knitting double-sided circular knitting machine is used, specifically a weft-knitting rib double-sided circular knitting machine. The first and second yarns are fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating, evenly spaced pattern in the weft direction. The knitting process employs a rib air-layer knitting technique, with three loop-forming systems completing a full structure. In the first loop-forming system, all upper and lower needles participate in the knitting, forming a 1+1 rib cross; in the second loop-forming system, only lower needles participate, with upper needles forming floats; in the third loop-forming system, only upper needles participate, with lower needles forming floats. In each loop-forming system, the third yarn, spandex elastic yarn, is simultaneously fed into the knitting area. After being guided by a yarn guide, the spandex elastic yarn is fed into the needle hooks of the knitting needles alongside the first or second yarn participating in the knitting. Before feeding, the spandex elastic yarn is actively unwound from the spandex stock, and the yarn feeding tension is controlled by a yarn storage device and a tension regulating device. The feeding tension of the spandex elastic yarn is controlled between 8cN and 12cN, and the draft ratio is controlled between 1.8 and 2.2. The weaving equipment uses a 12-needle / 25.4mm (i.e., 12 needles / inch) weft-knitting double-sided circular knitting machine. During the weaving process, the feeding tension of the first and second yarns is controlled at 3cN to 5cN, the tension at 20N to 30N, the bending depth at 2.5mm to 3.5mm, and the machine speed at 20 to 25 revolutions per minute. This weaving process forms a greige fabric with a double-layer air-layer structure, where the first and second yarns interweave to form the face layer and the bottom layer, and the third yarn is embedded between the face layer and the bottom layer in a sandwich state. In the greige fabric, the spandex elastic yarn extends continuously along each row of loops in the transverse direction and continuously extends along each column of loops in the longitudinal direction, forming a cross-woven, elastic mesh skeleton.

[0096] Finishing: The woven fabric undergoes finishing treatment. This includes sequential setting, dyeing, and drying. Setting is performed on a setting machine at a temperature of 150℃ to 180℃. Dyeing is carried out in a high-temperature, high-pressure dyeing machine at a temperature of 120℃ to 130℃ for 30 to 45 minutes. Drying is performed in a dryer at a temperature of 100℃ to 120℃. After finishing, the finished elastic air-layer fabric is obtained.

[0097] Example 6:

[0098] This embodiment provides a method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions. The method is used to prepare the fabric in any one of the above embodiments one to five.

[0099] The preparation method in this embodiment includes the following steps.

[0100] Prepare the yarns: Prepare modal fiber yarn as the first yarn, prepare cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, and prepare spandex elastic yarn as the third yarn.

[0101] The first yarn, Modal fiber yarn, is spun from Lenzing Modal fiber with a count of 40S (metric count) using the Siro compact spinning process. The second yarn, cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. Each fiber in this second yarn has a cross-shaped cross-section, and the fiber surface has four continuous grooves along the axial direction. This second yarn is a 75D / 72F (75 denier, 72 filaments) stretch textured yarn. The third yarn, spandex elastic yarn, is made from polyurethane elastic fiber with a fineness of 30D. Before use, these three yarns are wound onto their respective bobbins and placed on the yarn frame of a weft knitting circular knitting machine according to the weaving requirements.

[0102] Knitting: Knitting is performed using a weft-knitting double-sided circular knitting machine. This machine is a weft-knitting rib double-sided circular knitting machine with two needle beds: an upper needle bed and a lower needle cylinder. The needles in the upper needle bed are called upper needles, and the needles in the lower needle cylinder are called lower needles. The upper and lower needles are arranged opposite each other on the needle beds, with the upper needle hooks facing down and the lower needle hooks facing up. The needles on the two needle beds move in opposite directions.

[0103] The first and second yarns are drawn from the yarn frame and guided by their respective weft feeders and yarn guides. They are then fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating, evenly distributed manner along the weft direction. Specifically, the first and second yarns are arranged alternately in a 1:1 ratio and fed sequentially to adjacent needles along the weft direction. That is, the first needle feeds the first yarn, the second needle feeds the second yarn, the third needle feeds the first yarn, the fourth needle feeds the second yarn, and so on, resulting in a uniform, alternating arrangement of the first and second yarns around the entire circumference of the needle cylinder.

[0104] The third yarn, spandex elastic filament, is drawn from the yarn crease, guided by the yarn guide, and simultaneously fed into the knitting area using a constant tension active unwinding method. Before feeding, the spandex elastic filament is unwound from the spandex yarn cake and passes sequentially through the yarn storage device and tension adjustment device, with the feeding tension controlled between 8cN and 12cN. The feeding position of the spandex elastic filament is parallel to that of the first or second yarn, meaning that the spandex elastic filament and the first or second yarn enter the same needle hook.

[0105] The weaving technique employs a rib knitting method, with three loop-forming systems completing one full structure. The sequence of the loop-forming systems is as follows:

[0106] The first loop-forming system involves all purl and knit needles. In this system, purl and knit needles extend from the needle bed with the needle hooks in the open position. The first and second yarns are fed into the needle hooks of the purl and knit needles alternately, with spandex elastic yarn fed into the same needle hook alongside either the first or second yarn. Subsequently, the purl and knit needles descend simultaneously, forming a 1+1 rib pattern. Specifically, in the purl needles, the first or second yarn and spandex elastic yarn bend together to form the top layer loops, while in the knit needles, they bend together to form the bottom layer loops. The top layer loops and bottom layer loops are connected in this system through interlocking during the simultaneous knitting of the purl and knit needles.

[0107] The second loop-forming system: Only the knitting needle participates in the knitting process; the purl needles do not. In this system, the knitting needle extends from the cylinder with its hook open, while the purl needle retracts into the needle plate with its hook closed. The first and second yarns are fed into the knitting needle hook alternately, with the spandex elastic yarn fed into the same hook alongside either the first or second yarn. Since the purl needles do not participate in the knitting process, no yarn is fed into their hooks. The knitting needle then descends and bends the yarn, forming a new loop row in the bottom layer under the combined action of the first or second yarn and the spandex elastic yarn. This new bottom layer loop interlocks longitudinally with the bottom layer starting loop row already formed in the first loop-forming system. Simultaneously, at the corresponding positions on the purl needles, the first, second, and spandex elastic yarns do not form loops, but rather float across the stitch length between adjacent purl needles. This float extends laterally for a length equal to the stitch length between two adjacent purl needles.

[0108] The third loop-forming system: Only the purl needles participate in knitting; the knitting needles do not. In this system, the purl needles extend from the needle plate with the hooks open, while the knitting needles retract into the needle cylinder with the hooks closed. The first and second yarns are fed into the hooks of the purl needles alternately, with the spandex elastic yarn fed into the same hook alongside either the first or second yarn. Since the knitting needles do not participate in knitting, no yarn is fed into their hooks. Subsequently, the purl needles descend and bend the yarn, forming a new row of loops in the surface layer under the combined action of the first or second yarn and the spandex elastic yarn. These new surface layer loops are interlocked longitudinally with the initial row of loops already formed in the first loop-forming system. Simultaneously, at the corresponding positions on the knitting needles, the first, second, and spandex elastic yarns do not form loops, but rather float across the stitch length between adjacent knitting needles.

[0109] The three looping systems operate in a cyclical manner, following the sequence of the first looping system, the second looping system, and the third looping system, repeating the weaving process until the preset fabric length is reached.

[0110] The knitting equipment is a 12-needle / 25.4mm (i.e., 12 needles / inch) weft knitting double-sided circular knitting machine with a cylinder diameter of 762mm (30 inches). During the knitting process, the yarn tension of the first and second yarns is controlled at 3cN to 5cN, the traction force at 20N to 30N, the yarn bending depth at 2.5mm to 3.5mm, and the machine speed at 18 to 25 revolutions per minute.

[0111] Through the above-described weaving process, a greige fabric with a double-layer air-layer structure is formed. In the greige fabric, the first and second yarns interweave to form the face layer and the back layer. The face layer is composed of face layer loops formed by the first and second yarns in the up-needle arrangement, arranged horizontally and vertically. The back layer is composed of back layer loops formed by the first and second yarns in the down-needle arrangement, also arranged horizontally and vertically. The face layer and the back layer are connected to each other by connecting loops formed by the simultaneous weaving of the up-needle and down-needle in the first loop-forming system. Due to the presence of float yarns in the second and third loop-forming systems, an air gap is formed between the face layer and the back layer. Spandex elastic yarn is embedded between the face layer and the back layer in a sandwich state, and is also distributed in the loops of both the face layer and the back layer, forming a continuously extending elastic network in both the horizontal and vertical directions.

[0112] Finishing: The finishing process is carried out on the woven fabric. The finishing process includes setting, dyeing and drying in sequence.

[0113] Setting Process: The woven fabric is fed into a setting machine for heat setting. The setting machine is a hot air tenter setter. The fabric is guided into the setting machine's oven by guide rollers and heated by circulating hot air. The setting temperature is 150℃ to 180℃, and the setting speed is 25m to 35m per minute. During the setting process, the fabric is stretched laterally by a tenter unit to achieve the preset width. After setting, the fabric is cooled by cooling rollers before being discharged.

[0114] Dyeing Treatment: The greige fabric after setting is placed into a high-temperature, high-pressure dyeing machine for dyeing. The dyeing machine is a high-temperature, high-pressure overflow dyeing machine. The dyeing liquor ratio is 1:10 to 1:12, that is, the ratio of greige fabric mass to dye liquor volume is 1:10 to 1:12. The dye liquor is prepared by dyes, auxiliaries, and water. The dyes are selected according to the desired color, using a combination of disperse dyes (for polyester fibers) and reactive dyes (for modal fibers). Auxiliaries include leveling agents, dispersants, penetrants, and acetic acid. Acetic acid is used to adjust the pH of the dye liquor to 4.5 to 5.5. During dyeing, the greige fabric is placed into the dyeing machine, the dyeing machine cylinder cover is closed, and the dye liquor temperature is raised to 120°C to 130°C at a heating rate of 1.0°C to 1.5°C per minute, and held at this temperature for 35 to 45 minutes. After the holding period, the dye liquor temperature is lowered to below 60°C at a cooling rate of 1.0°C to 1.5°C per minute. After dyeing, drain the dye bath and wash the fabric with clean water to remove excess dye and residual auxiliaries. The washing time is 10 to 20 minutes.

[0115] Drying process: The dyed fabric is fed into a dryer for drying. The dryer is a hot air dryer. The drying temperature is 100℃ to 120℃, and the drying time is 3 to 5 minutes. The fabric is heated by hot air circulation in the dryer to remove moisture and achieve the specified moisture regain rate. After the drying process is completed, the finished elastic air-layer fabric is obtained.

[0116] In the above finishing processes, the process parameters such as temperature, time, and speed of the setting, dyeing, and drying processes are adjusted according to the weight of the greige fabric, fiber type, and required finished product specifications. The temperature of the setting process is controlled within the range of 150℃ to 180℃, the temperature of the dyeing process is controlled within the range of 120℃ to 130℃, and the temperature of the drying process is controlled within the range of 100℃ to 120℃. The connection between each process adopts continuous production or intermittent production methods.

[0117] Example 7:

[0118] This embodiment provides a method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions. The method is used to prepare the fabric in any one of the above embodiments one to five.

[0119] The difference between the preparation method in this embodiment and that in Embodiment Six lies in the specific selection of the weaving equipment and the refined adjustment of the weaving process parameters, in order to meet the preparation needs of fabrics of different specifications.

[0120] The preparation method in this embodiment includes the following steps.

[0121] Prepare the yarns: Prepare modal fiber yarn as the first yarn, prepare cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, and prepare spandex elastic yarn as the third yarn.

[0122] The first yarn, Modal fiber yarn, is spun from Lenzing Modal fiber with a yarn count of 40S (metric count). It is produced using the Siro compact spinning process, with a single yarn breaking strength of 22cN / tex to 26cN / tex and a yarn evenness CV value of no more than 12%. The second yarn, cross-section moisture-wicking and quick-drying polyester fiber yarn, is made from polyester filaments spun using a cross-section spinneret. Each fiber in this second yarn has a cross-shaped cross-section, with four continuous grooves along the axial direction on the fiber surface. This second yarn is a 75D / 72F (75 denier, 72 filaments) stretch textured yarn with a breaking strength of 3.5cN / dtex to 4.0cN / dtex and a breaking elongation of 25% to 30%. The third yarn, spandex elastic yarn, is made from polyurethane elastic fiber with a fineness of 30D, a breaking elongation of 450% to 550%, and a resilience of no less than 95%.

[0123] Before use, the three types of yarn should be treated as follows: the first and second yarns should be equilibrated for at least 24 hours in an environment with a relative humidity of 65%±5% and a temperature of 20℃±2℃. Before use, the third yarn, spandex elastic yarn, should have its unwinding tension checked to ensure that the surface of the spandex yarn cake is undamaged and free of adhesion. The three yarns should be wound separately onto their respective yarn bobbins and placed on the yarn frame of the weft knitting double-sided circular knitting machine according to the weaving requirements.

[0124] Weaving: Weaving is performed using a weft knitting double-sided circular knitting machine. The weft knitting double-sided circular knitting machine is a weft knitting rib double-sided circular knitting machine. In this embodiment, different machine sizes are used on the weft knitting double-sided circular knitting machine to accommodate the preparation of fabrics of different specifications, specifically including the following methods.

[0125] Option 1: Use a weft-knitted rib double-sided circular knitting machine with a gauge of 12 needles / 25.4mm (i.e., 12 needles / inch), a cylinder diameter of 762mm (30 inches), and a total of 720 needles (360 purl needles and 360 knit needles). This gauge is suitable for preparing medium-weight fabrics with a weight of 280g / m² to 320g / m².

[0126] Option 2: Use a weft-knitted rib double-sided circular knitting machine with a gauge of 14 needles / 25.4mm (i.e., 14 needles / inch), a cylinder diameter of 762mm (30 inches), and a total of 840 needles (420 purl needles and 420 knit needles). This gauge is suitable for preparing lightweight fabrics with a weight of 180g / m² to 220g / m².

[0127] Option 3: Use a weft-knitted rib double-sided circular knitting machine with a gauge of 16 needles / 25.4mm (i.e., 16 needles / inch), a cylinder diameter of 762mm (30 inches), and a total of 960 needles (480 purl needles and 480 knit needles). This gauge is suitable for preparing ultra-thin fabrics with a weight of 150g / m² to 180g / m².

[0128] Regardless of which type of weft knitting double-sided circular knitting machine is used, the knitting principle and yarn feeding method are the same, as detailed below:

[0129] The first and second yarns are drawn from the yarn frame and guided by their respective weft feeders and yarn guides. They are then fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating, evenly distributed pattern along the weft direction. Specifically, the first and second yarns are arranged alternately in a 1:1 ratio and fed sequentially to adjacent needles along the weft direction. That is, the first needle feeds the first yarn, the second needle feeds the second yarn, the third needle feeds the first yarn, the fourth needle feeds the second yarn, and so on, with the first and second yarns evenly distributed alternately around the entire circumference of the needle cylinder. An electronic weft feeder is used, with a single yarn tension control accuracy of ±0.5cN.

[0130] The third yarn, spandex elastic filament, is drawn from the yarn crease, guided by the yarn guide, and simultaneously fed into the knitting area using a constant tension active unwinding method. Before feeding, the spandex elastic filament is unwound from the spandex yarn cake and passes sequentially through the yarn storage device and tension adjustment device. The feeding tension of the spandex elastic filament is adjusted according to different schemes: in Scheme 1, the feeding tension is controlled at 8cN to 10cN; in Scheme 2, the feeding tension is controlled at 7cN to 9cN; and in Scheme 3, the feeding tension is controlled at 6cN to 8cN. The draft ratio of the spandex elastic filament is adjusted according to different schemes: in Scheme 1, the draft ratio is controlled at 2.0 to 2.5; in Scheme 2, the draft ratio is controlled at 1.8 to 2.2; and in Scheme 3, the draft ratio is controlled at 1.5 to 2.0. The feeding position of the spandex elastic filament is parallel to that of the first or second yarn, meaning that the spandex elastic filament and the first or second yarn enter the same needle hook.

[0131] The knitting process employs a rib air layer knitting technique, with three loop systems completing a full structure. The operating sequence and specific knitting actions of the loop systems are the same as in Example 6: in the first loop system, all knit and purl needles participate in the knitting, forming a 1+1 rib row; in the second loop system, only purl needles participate in the knitting, with knit needles forming floats; in the third loop system, only purl needles participate in the knitting, with purl needles forming floats. The three loop systems operate in a cyclical manner, following the sequence of the first, second, and third loop systems.

[0132] During the weaving process, the various process parameters are adjusted accordingly based on different machine sizes:

[0133] Option 1 (12 needles / 25.4mm): Yarn tension is 3.5cN to 4.5cN, pulling force is 22N to 28N, yarn bending depth is 2.8mm to 3.2mm, and machine speed is 18 to 22 revolutions per minute.

[0134] Option 2 (14 needles / 25.4mm): Yarn tension is 3.0cN to 4.0cN, pulling force is 18N to 25N, yarn bending depth is 2.4mm to 2.8mm, and machine speed is 20 to 25 revolutions per minute.

[0135] Option 3 (16 needles / 25.4mm): Yarn tension is 2.5cN to 3.5cN, pulling force is 15N to 22N, yarn bending depth is 2.0mm to 2.5mm, and machine speed is 22 to 28 revolutions per minute.

[0136] The bend depth is defined as the distance the needle hook moves downwards relative to the sinker's grip point as the knitting needle descends from its highest point to its lowest bend. The bend depth determines the loop length, which in turn affects the fabric's weight and density. The loop length L (unit: mm) is calculated using the following formula:

[0137] L = 2 × (S + D) × π / N

[0138] Where S is the yarn bending depth (unit: mm), D is the needle hook diameter (unit: mm), and N is the machine size (unit: needle / 25.4 mm).

[0139] Specifically, the coil length control range for each scheme is as follows: the coil length is controlled from 4.5mm to 5.5mm in Scheme 1, from 3.8mm to 4.5mm in Scheme 2, and from 3.0mm to 3.8mm in Scheme 3.

[0140] Through the above weaving process, a greige fabric with a double-layer air layer structure is formed. In the greige fabric, the first yarn and the second yarn interweave to form the surface layer and the bottom layer, and the spandex elastic yarn is embedded between the surface layer and the bottom layer in a sandwich state.

[0141] Finishing: The finishing process is carried out on the woven fabric. The finishing process includes setting, dyeing and drying in sequence.

[0142] Setting Process: The woven fabric is fed into a setting machine for heat setting. The setting machine is a hot air tenter setter with eight drying chambers, each with independently controllable temperature. The fabric is guided into the setting machine's drying chambers by guide rollers and heated by circulating hot air. The setting temperature and speed for each scheme are adjusted according to the fabric weight and machine size: Scheme 1: Setting temperature 160℃ to 175℃, setting speed 25m to 30m / min; Scheme 2: Setting temperature 155℃ to 170℃, setting speed 30m to 35m / min; Scheme 3: Setting temperature 150℃ to 165℃, setting speed 35m to 40m / min. During the setting process, the fabric is stretched laterally by a tenter unit, with the overfeed rate controlled within the range of -3% to +5%, ensuring the fabric width reaches the preset size. After the shaping process is completed, the fabric is cooled to below 60°C by cooling rollers before being released from the press.

[0143] Dyeing Treatment: The greige fabric after setting is placed into a high-temperature, high-pressure dyeing machine for dyeing. The dyeing machine is a high-temperature, high-pressure overflow dyeing machine with a dyeing vat capacity of 200kg to 500kg. The dyeing liquor ratio is 1:10 to 1:12. The dye liquor is prepared from dyes, auxiliaries, and water. The dyes used are a combination of disperse dyes (for polyester fibers) and reactive dyes (for modal fibers) selected according to the desired color. The amount of disperse dyes used is 0.5% to 3.0% of the greige fabric mass, and the amount of reactive dyes used is 0.5% to 3.0% of the greige fabric mass. Auxiliaries include leveling agent (1.0g / L to 2.0g / L), dispersant (0.5g / L to 1.5g / L), penetrant (0.5g / L to 1.0g / L), and acetic acid (used to adjust the pH value). The amount of acetic acid used is determined according to the initial pH value of the dye liquor, adjusting the pH value of the dye liquor to 4.5 to 5.5.

[0144] During dyeing, the greige fabric is placed into the dyeing machine, the dyeing machine cylinder cover is closed, and the dye liquor temperature is raised to 120℃ to 130℃ at a heating rate of 1.0℃ to 1.5℃ per minute, and held at this temperature for 35 to 45 minutes. After holding, the dye liquor temperature is lowered to below 60℃ at a cooling rate of 1.0℃ to 1.5℃ per minute. After dyeing, the dye liquor is drained, and the greige fabric is washed with clean water. The washing process involves hot water washing (60℃ to 80℃, 10 minutes), warm water washing (40℃ to 50℃, 10 minutes), and cold water washing (room temperature, 10 minutes) to remove floating dye and residual auxiliaries. After washing, a reduction cleaning treatment is performed. The reduction cleaning solution is prepared with sodium hydroxide (2.0 g / L) and sodium hydrosulfite (2.0 g / L), and the cleaning temperature is 80℃ to 85℃ for 15 to 20 minutes. After the initial cleaning is complete, rinse again with clean water until neutral.

[0145] Drying Process: The dyed fabric is fed into a dryer for drying. The dryer is a hot air dryer with three drying chambers. The drying temperature is 100℃ to 120℃, and the drying time is 3 to 5 minutes. The fabric is heated by circulating hot air in the dryer to remove moisture and achieve the specified moisture regain (8% to 10% for modal fibers). After drying, the finished elastic air-layer fabric is obtained.

[0146] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A type of elastic air-layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions, characterized in that, It includes a double-layer air layer structure formed by weft-knitted double-sided structure, the fabric being woven from a weft yarn system, the weft yarn system being composed of a first yarn, a second yarn and a third yarn; The first yarn is modal fiber yarn, the second yarn is cross-section moisture-wicking and quick-drying polyester fiber yarn, and the third yarn is spandex elastic yarn; The first yarn and the second yarn are arranged in a uniform, alternating pattern in the weft direction to participate in weaving to form the surface layer and the bottom layer of the double-layer air layer structure. The third yarn is simultaneously fed in and embedded between the surface layer and the bottom layer during the weaving process.

2. The elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 1, characterized in that, The cross-section moisture-absorbing and quick-drying polyester fiber yarn has a cross-shaped cross-section for each fiber, and multiple continuous grooves are formed on the surface of each fiber along the axial direction.

3. The elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 1, characterized in that, The ratio of the number of the first yarn to the number of the second yarn in the weft direction is 1:

1.

4. The elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 1, characterized in that, The double-layer air layer structure is specifically a weft-knitted rib air layer structure.

5. The elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 1, characterized in that, The third yarn extends and embeds itself continuously in the fabric in both the transverse and longitudinal directions.

6. The elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 1, characterized in that, The top layer and the bottom layer are separated by connecting yarns to form a closed air gap.

7. A method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions, applicable to the elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions as described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1. Prepare modal fiber yarn as the first yarn, prepare cross-section moisture-wicking and quick-drying polyester fiber yarn as the second yarn, and prepare spandex elastic yarn as the third yarn. S2. Weft knitting double-sided circular knitting machine is used for knitting. The first yarn and the second yarn are fed into the upper needle plate and lower needle cylinder of the knitting area in an alternating and uniform manner in the weft direction. At the same time, the third yarn is fed into the knitting area so that the third yarn is sandwiched between the upper and lower layers of the fabric during the looping process. S3. A fabric with a double-layer air layer structure is formed by double-sided weaving process, in which the first yarn and the second yarn are interwoven to form a surface layer and a bottom layer, and the third yarn is embedded between the surface layer and the bottom layer in a sandwich state. S4. Perform finishing treatment on the woven fabric to obtain the elastic air layer fabric.

8. The method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 7, characterized in that, The weft knitting double-sided circular knitting machine is a weft knitting rib double-sided circular knitting machine, and the double-sided knitting process is a rib air layer knitting process.

9. The method for preparing an elastic air layer fabric with breathable, sweat-wicking, moisture-wicking, and quick-drying functions according to claim 7, characterized in that, The finishing process includes a shaping process, a dyeing process, and a drying process performed sequentially.

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