A method of weaving an enhanced three-dimensional fabric

Abstract

The present application relates to the technical field of textiles, and particularly to a weaving method of a reinforced three-dimensional fabric, so as to alleviate the problems of existing three-dimensional fabric, such as support force attenuation, resilience performance decline, and difficulty in meeting the needs of high load or high resilience application scenarios. The weaving method comprises a basic weaving step and a reinforcing treatment step, and the reinforcing treatment step comprises: forming a solidified reinforcing body in situ at a node area where a face tissue, a middle filament bundle and a bottom tissue intersect, and the solidified reinforcing body bonds the fibers in the node area. The solidified reinforcing body covers and bonds all the fibers in the node area, and microscopically constructs a micro-zone composite material unit with a polymer as a continuous matrix and fibers as a reinforcing phase, thereby significantly improving the overall support force, shape stability and deformation resistance of the fabric.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and in particular to a method for weaving reinforced three-dimensional fabrics. Background Technology

[0002] Three-dimensional spacer fabrics are three-dimensional textile structures composed of an upper layer structure, a lower layer structure, and medium-density strands connecting the two. The continuous spatial network formed within them endows the fabric with excellent breathability, cushioning, and elastic recovery, thus making them widely used in mattresses, furniture upholstery, automotive interiors, sports protective gear, and composite material reinforcements.

[0003] The nodes of this type of fabric are prone to weakening of support and reduction of resilience, making it difficult to meet the needs of high load or high resilience application scenarios. Summary of the Invention

[0004] This invention provides an enhanced three-dimensional fabric to alleviate the problems of weakened support and reduced resilience of existing three-dimensional fabrics, which make it difficult to meet the needs of high-load or high-resilience application scenarios.

[0005] To alleviate the above-mentioned technical problems, the technical solution provided by the present invention is as follows: A method for weaving an enhanced three-dimensional fabric includes a basic weaving step and a reinforcement treatment step. The basic weaving steps include: The face weaving mechanism and the base weaving mechanism work together with hooks and sinkers to complete the looping, unlooping and drawing of the yarn, and weave the face weaving and base weaving respectively; The medium-tow weaving mechanism reciprocates between the surface weaving mechanism and the base weaving mechanism, simultaneously participating in the weaving of the surface and base structures, and forming upright medium-tows in between, thereby forming a three-dimensional fabric structure. The enhancement process includes: In the node region where the face structure, middle fiber bundle and base structure intersect, a cured reinforcement is formed in situ, and the cured reinforcement bonds the fibers in the node region.

[0006] Furthermore, In the reinforcement process, the fiber in the node region where the face structure, middle fiber bundle and base structure intersect is impregnated with resin at least once and then cured by heating and drying or UV curing to form a cured reinforcement. The cured reinforcement covers and bonds the fibers in the node region.

[0007] Furthermore, The heating and drying temperature is 6℃~8℃, and the drying time is from seconds to minutes; The ultraviolet curing uses UV adhesive, which is cured by irradiation with an ultraviolet lamp.

[0008] Furthermore, The impregnation method includes one or more of the following: dip coating, brush coating, spray coating, coating or impregnation.

[0009] Furthermore, The adhesive material includes one or more of TPU, EVA, PVA, and PE.

[0010] Furthermore, In the enhancement processing step The hot melt monomer is introduced into the node area where the face structure, middle yarn bundle and bottom structure intersect according to the preset weaving method through the hot melt monomer introduction mechanism; The woven fabric is heat-treated to melt at least part of the hot melt monomer, and the melt flows and wets the fiber surface and gaps in the node region. Cooling and curing are performed to form an integrated cured reinforcement in the node region.

[0011] Furthermore, The preset weaving method is as follows: the hot melt monomer is woven into the fabric in the form of linear yarn.

[0012] Furthermore, The preset weaving method is as follows: the hot melt monomer is woven into the fabric in the form of a lock ring, the lock ring passes through the surface node, surrounds or interweaves the middle yarn bundle, and then passes through the corresponding node of the bottom layer.

[0013] Furthermore, The preset weaving method is as follows: the hot melt monomer is woven into the fabric at an angle inclined relative to the middle yarn bundle, and the hot melt monomer is connected to the corner area between the face fabric and / or the base fabric and the middle yarn bundle.

[0014] Furthermore, The hot-melt monomer is introduced by weft insertion, warp insertion, or knitting, and forms a cross, wrap, or knot structure with the yarns of the face or base structure in the node area.

[0015] Furthermore, The hot-melt monomer is one of a fully fused wire, a core-sheath structured wire, or a partially fused wire; The core-sheath structure includes a core layer and a hot-melt material outer layer covering the core layer.

[0016] The beneficial effects of this invention are analyzed as follows: In terms of mechanical properties, the cured reinforcement, by encapsulating and bonding all fibers within the node region, constructs a micro-composite unit at the microscopic level, with the polymer as the continuous matrix and fibers as the reinforcing phase. The direct effect is a fundamental enhancement of the node's compressive stiffness, flexural strength, and shear resistance, effectively suppressing failure modes such as relative slippage and local buckling of yarns under continuous or dynamic loads, thereby significantly improving the fabric's overall support, shape stability, and resistance to deformation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of the present invention, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a flowchart of the weaving method for the enhanced three-dimensional fabric provided in this embodiment; Figure 2 This is a schematic diagram of the overall structure of the weaving unit of the three-dimensional fabric in this embodiment; Figure 3 This is a schematic diagram of the overall structure of the weaving unit of the three-dimensional fabric in this embodiment; Figure 4 This is a schematic diagram of the structure of the cured reinforcement attached to the surface node in this embodiment; Figure 5 This is a schematic diagram of the structure in this embodiment where the cured reinforcement is attached to the surface node and the half of the surface tissue; Figure 6 This is a schematic diagram of the structure in this embodiment where the cured reinforcement is attached to the surface node and the surface tissue connection edge; Figure 7 This is a schematic diagram of the structure in this embodiment where the cured reinforcement is attached to the face node and the bottom node; Figure 8 This is a schematic diagram of the cured reinforcement attached to the overall structure in this embodiment.

[0019] Icons: 100 - Face structure; 110 - Face node; 120 - Face structure connection edge; 121 - Face structure half edge; 200 - Bottom structure; 210 - Bottom node; 220 - Bottom structure connection edge; 221 - Bottom structure half edge; 300 - Middle fiber bundle; 400 - Cured reinforcement. Detailed Implementation

[0020] Example 1 This embodiment provides an enhanced three-dimensional fabric; please refer to [other examples]. Figures 1-8The basic structural unit of this fabric consists of multiple woven units arranged continuously and repeatedly along the warp and weft directions in a horizontal plane. Each woven unit includes an upper layer structure 100 and a lower layer structure 100 formed by warp and weft yarns interlacing according to a specific weaving pattern, as well as a middle yarn bundle 300 positioned between the intersections of the upper and lower layers. The specific weaving pattern can be, for example, plain weave, twill weave, satin weave, or variations thereof. The middle yarn bundle 300 is typically positioned upright or inclined between the intersections of the upper and lower layers, thereby forming a stable three-dimensional spatial structure between the upper and lower layers.

[0021] The core improvement of this embodiment lies in constructing a cured reinforcement 400 at the junction of the facet 100, the middle tow 300, and the base 200. This cured reinforcement 400 tightly encapsulates, impregnates, and bonds the fiber assembly within the junction area through physical and / or chemical action. The fiber assembly includes the facet 100 yarn, the middle tow 300, and possibly the base 200 yarn. Its mechanism is as follows: by introducing a reinforcing phase material with adhesiveness and a certain stiffness, the fiber bundles, which were originally mainly bound by friction and geometric interlocking, are transformed into a localized micro-area composite material. In this composite material unit, the fibers, as the reinforcing phase, provide tensile strength, while the cured reinforcement material, as the matrix phase, plays a role in transferring stress, constraining the relative displacement of the fibers, and resisting compression and shear deformation. This fundamentally strengthens the mechanical integrity of the junction, effectively suppresses the failure modes of the junction under load, and improves the overall support, deformation resistance, and structural durability of the fabric.

[0022] This reinforced 3D fabric is suitable for various high-load, high-resilience, or long-term dynamic use scenarios, including but not limited to: vehicle seat ventilation pads, medical mattresses and anti-decubitus pads, sports protective gear and shoe insole linings, home mattress and sofa filling layers, and composite prefabricated reinforcements. While maintaining the inherent breathability and cushioning properties of 3D fabrics, its structure significantly improves mechanical durability through node reinforcement, meeting the comprehensive needs of automotive, medical, sports, home, and industrial fields for long-term material support, shape stability, and comfort. By setting solidified reinforcements in the node areas, this fabric achieves strong fiber bonding and uniform stress transfer at the nodes, effectively inhibiting yarn slippage, plastic deformation, and fatigue failure. Its structure maintains high resilience and low permanent deformation under long-term compression, bending, and multi-directional loads, while retaining its original breathability and lightweight characteristics. This design significantly improves the overall support, shear stability, and service life of the fabric, balancing mechanical reliability and user comfort under dynamic environments.

[0023] In some embodiments, the enhanced three-dimensional fabric provided in this application can be applied to vehicle seats.

[0024] In some embodiments, the reinforced three-dimensional fabric provided in this application can be applied to vehicle seats and cooperate with other components in the vehicle seats to achieve ventilation and seat support functions of the vehicle seats.

[0025] In some embodiments, the reinforced three-dimensional fabric can serve as a ventilation layer or component of a vehicle seat. Exemplarily, the vehicle seat may include a seat cover, seat frame, seat foam, and ventilation components. The ventilation components may include sub-components such as a fan and the reinforced three-dimensional fabric. Gas is driven by the fan and circulates freely within the reinforced three-dimensional fabric to achieve functions such as blowing and / or suction in the vehicle seat.

[0026] To implement node enhancements more precisely, this embodiment defines the concept of a node region. A node region is defined as one or more of the following specific, operable physical regions: Surface node 110: Specifically refers to the location where the yarn intersection (or specific position) of the upper layer 100 meets and is fixed to the upper end of the middle yarn bundle 300. This is the primary interface for the transfer of load from the surface layer to the middle yarn bundle 300.

[0027] Bottom node 210: Specifically refers to the location where the yarn intersection of the lower layer structure 100 and the lower end of the middle yarn bundle 300 meet and are fixed. This is the terminal interface for the load to be transferred from the middle yarn bundle 300 to the bottom layer.

[0028] Surface weave connection edge 120: refers to the yarn segment connecting two adjacent surface nodes 110 within the plane of the upper surface weave 100, such as the warp or weft yarn segment between two adjacent interlacing points. Strengthening this area helps improve the overall integrity and bending stiffness of the surface layer between nodes.

[0029] Bottom weave connecting edge 220: refers to the yarn segment connecting two adjacent bottom nodes 210 within the plane of the lower layer weave 100. Its function is similar to that of the surface weave connecting edge 120, used to enhance the local stiffness of the bottom layer.

[0030] Corner zone: This refers to the angular space formed between the face fabric plane 100 or the base fabric plane 200 and the axial direction of the middle yarn bundle 300. When the fabric is subjected to non-perpendicular loads, such as lateral compression, shearing, or torsion, stress concentration is significant in this area, making it a high-risk area for yarn slippage and structural distortion.

[0031] The coating area of ​​the specific cured reinforcement 400 is described below with reference to the accompanying drawings: Figure 5 The reinforcement 400 is bonded to the surface node 110 area for curing. Figure 6 The curing reinforcement 400 is adhered to the face node 110 and the face structure half 121 that is continuous with the face node 110. Figure 7The curing reinforcement 400 is adhered to the surface node 110 and the surface structure connection edge 120 that is continuous with the surface node 110. Figure 8 The reinforcement 400 is bonded to the face node 110 and the bottom node 210 for curing.

[0032] By enhancing the different sub-regions individually or in combination, multi-dimensional reinforcement can be achieved, thereby more comprehensively addressing complex load conditions.

[0033] In this embodiment, the cured reinforcement 400 can be formed by impregnation, which is essentially a finishing process. This method offers high flexibility, allowing for selective reinforcement based on actual test weaknesses in the fabric. It is also suitable for rapidly adjusting reinforcement schemes in small-batch, multi-variety production models. During operation, the amount and position of the adhesive can be controlled using precision impregnation equipment. The adhesive can be one or more of TPU (thermoplastic polyurethane), EVA (ethylene-vinyl acetate copolymer), PVA (polyvinyl alcohol), and PE (polyethylene), or modified starch, such as sodium hypochlorite-treated starch, acetate starch, hydroxypropyl starch, or sodium tripolyphosphate-treated cross-linked starch.

[0034] However, the reinforcement formed by the impregnation method is an external bonding, and its bonding interface mainly relies on the physical adhesion of the adhesive to the fiber surface and possible limited chemical bonding. Under long-term dynamic fatigue loads, humid and hot environments, or large deformations, this interface may become a weak point, with the potential risk of the adhesive layer peeling off or detaching from the fiber surface.

[0035] To address the reliability issue of interface bonding, this embodiment provides an alternative reinforcement strategy: the cured reinforcement 400 is formed by melting and solidifying a thermoplastic monomer woven into the fabric structure through subsequent heat treatment. Here, the thermoplastic monomer refers to a linear textile material with thermoplastic properties that can melt and flow at a specific temperature. Specifically, while weaving the three-dimensional fabric, these thermoplastic monomers are woven into predetermined node regions as special functional yarns according to a preset path and method, becoming an integral part of the fabric structure. After weaving, the entire fabric or the portion containing the thermoplastic monomer is subjected to controlled heat treatment, such as hot air baking, infrared irradiation, or passing through hot rollers. During the heat treatment, the thermoplastic monomer melts entirely or partially. The melt, due to its fluidity and surface tension, wets and coats all fiber surfaces in contact with it within the node region, and even penetrates into the gaps within the fiber bundles through capillary action. Subsequently, after a cooling stage, the melt re-solidifies, thereby forming a micro-composite unit in situ within the node region, with the thermoplastic polymer as the continuous matrix and the original fibers as the dispersed reinforcing phase.

[0036] The specific material form of the hot melt monomer can be selected and designed according to performance, cost and process requirements.

[0037] One method is the fully melt-fused filament, where the entire monofilament or multifilament is made of the same thermoplastic polymer material. It melts as a whole during heat treatment, has good fluidity, and is easy to form.

[0038] Another approach is the core-sheath structured yarn, which consists of two parts: a core layer and a surface layer. The core layer is typically made of polymer materials with high strength, modulus, or special functions, such as PET (polyester), PA (polyamide), and PP (polypropylene). Its main function is to maintain the processability of the yarn during weaving and provide partial skeletal support in the final structure. The surface layer is composed of low-melting-point thermoplastic materials, such as TPU (thermoplastic polyurethane), EVA (ethylene-vinyl acetate copolymer), and Co-PA (copolyamide). During heat treatment, the sheath layer melts and flows, acting as a binder, while the core layer remains solid. This achieves effective bonding while preserving a certain degree of structural stiffness and morphological stability in the node area, avoiding excessive softening or collapse of the nodes that might occur with fully fused yarn.

[0039] Another approach is to use partially melted fibers, such as bicomponent side-by-side or island-type fibers, in which one component melts at a heat treatment temperature as the binder phase, while the other component remains unmelted as the retainer phase.

[0040] The way hot-melt monomers are introduced into the nodal region directly affects the spatial morphology and reinforcement effect of the final reinforcement. Therefore, this embodiment provides a detailed description of the introduction method of hot-melt monomers: One basic approach is the linear introduction method, where the thermoplastic monomer is treated as a regular yarn and woven linearly through the node areas according to the fabric structure. For example, in a weave of 100 or 200, a weft or warp thermoplastic yarn is introduced at a specific target location. The thermoplastic yarn can protrude from the fabric surface, and the protruding part can serve as a thermoplastic marker. After heat treatment of the marker, the protruding part melts to form an adhesive attached to the fabric surface.

[0041] To achieve stronger three-dimensional spatial constraint and anchoring effects, the locking ring introduction method is preferred in the optional schemes of this embodiment. This method weaves the hot-melt monomer into an independent ring structure, which is placed within the node space during the weaving process. Its typical movement path is as follows: the locking ring enters from a face node 110 of the face structure 100, then interacts with the middle yarn bundle 300 by wrapping, weaving, or knotting, and then continues downward through the corresponding bottom node 210 on the bottom structure 200, ultimately connecting the ends of the locking ring to form a closed loop, or forming a stable ring structure through self-weaving. In this way, the locking ring acts like a small hoop, tightly connecting the face node 110, the middle yarn bundle 300 segment, and the bottom node 210 in three-dimensional space. In this embodiment, the locking ring can be completely embedded in the fabric or have its ends protruding from the fabric surface. When the end of the locking ring protrudes from the fabric surface, the protruding part can be melted after controlled heat treatment to form an adhesive attached to the fabric surface.

[0042] The specific geometry of the locking ring can be designed based on the technological capabilities of the weaving machinery and the required mechanical properties. For example: O-rings: the simplest type of ring, easy to form, and provide uniform circumferential constraint.

[0043] Spiral ring: It has a spiral structure like a spring and has a certain degree of elasticity in the axial direction. It can allow small elastic deformation of the nodes while constraining them, which helps with energy absorption.

[0044] Figure-eight ring: Its intersecting structure provides self-locking and higher structural stability, and can more effectively resist the opening and deformation of the ring itself.

[0045] Traditional reinforcement methods for three-dimensional fabrics often focus on improving the compressive stiffness of nodes in the vertical direction, but pay insufficient attention to the performance of nodes under oblique forces. When the fabric is subjected to lateral compression, shear, or torsional loads, the corner area between the surface or bottom layer and the middle yarn bundle 300 is a critical area for stress concentration and relative shear slip. To compensate for this deficiency, this embodiment proposes a reinforcement scheme for the corner area: when weaving the hot-melt monomers, they are arranged at an angle inclined to the axis of the middle yarn bundle 300 in the corner area. Specifically, the hot-melt monomers can obliquely connect the surface weave yarn 100 and the adjacent middle yarn bundle 300 segment, and / or obliquely connect the bottom weave yarn 200 and the adjacent middle yarn bundle 300 segment. The obliquely arranged hot-melt monomers include those completely embedded in the fabric or those with ends protruding from the fabric surface. When the protruding parts of the obliquely arranged hot-melt monomers are heated and melted, they can form an adhesive attached to the fabric surface. After melting and solidification, this diagonally arranged hot-melt material forms a structure similar to diagonal braces or reinforcing ribs in the corner area. When this area is subjected to shear force, these diagonally arranged reinforcements can more effectively withstand tensile and compressive stresses, thereby significantly improving the node's ability to resist in-plane shear and overall torsional deformation. This expands the mechanical properties of the three-dimensional fabric from primarily resisting vertical compression to possessing good multidimensional stability.

[0046] Besides improving stiffness and strength, maintaining good resilience and comfort of the fabric is equally important. Therefore, this embodiment requires that the raw materials used to form the cured reinforcement 400 should contain colloids or polymers with excellent elastic recovery properties. Thus, when the nodes deform under external force, not only can the fibers themselves rebound, but the elastic reinforcement material encapsulating them also provides restoring force, synergistically promoting the nodes to return to their original shape. Specifically, the cured reinforcement 400 can be formed from a variety of hot-melt polymer materials, such as: soft and wear-resistant thermoplastic polyurethane, lightweight and inexpensive polyolefin elastomers, ethylene-vinyl acetate copolymers with good adhesion, high-strength polyamides, or polyesters, etc. These materials can be used alone or after blending and modification.

[0047] When using heat treatment to melt and solidify the hot-melt monomers, the process window must be strictly controlled to ensure that the reinforcement process does not cause thermal damage to the main structure of the fabric. Therefore, the melting point of the selected hot-melt monomer material must be lower than the softening point of conventional yarns constituting the face structure (100), base structure (200), such as polyester, nylon, and polypropylene, and the medium tow (300). This condition ensures that during heat treatment, the hot-melt material melts and flows first to complete bonding, while the conventional yarns constituting the fabric skeleton maintain their solid state and original mechanical properties, without softening or deformation. This ensures the feasibility of the reinforcement process and the integrity of the basic fabric structure.

[0048] Example 2 This embodiment provides a method for weaving an enhanced three-dimensional fabric. For details, please refer to [link to relevant documentation]. Figure 1 This includes basic weaving steps and reinforcing treatment steps. The basic weaving steps include: S1: The 100-layer knitting mechanism and the 200-layer knitting mechanism complete the looping, looping and pulling of the yarn through the cooperation of hooks and sinkers, and respectively weave the 100-layer knitting mechanism and the 200-layer knitting mechanism. S2: The 300 medium yarn bundle weaving mechanism reciprocates between the 100 surface weaving mechanism and the 200 base weaving mechanism, and participates in the weaving of the 100 surface weaving mechanism and the 200 base weaving mechanism at the same time, and forms an upright medium yarn bundle 300 in between, thereby forming a three-dimensional fabric structure. The enhancement processing steps include: S3: In the node region where the face structure 100, the middle fiber bundle 300 and the base structure 200 intersect, a cured reinforcement 400 is formed in situ, and the cured reinforcement 400 bonds the fibers in the node region.

[0049] Regarding the enhancement process step S3, this solution provides two enhancement methods, specifically: S31: Post-impregnation curing method In the pre-defined node area where the face fabric 100, middle yarn bundle 300, and base fabric 200 intersect, at least one precise impregnation operation is performed using automated or semi-automated equipment to apply a predetermined amount of adhesive to the target location. Finally, the adhesive is cured using an appropriate energy supply method. There are two main curing methods: one is heating and drying, which uses heat energy to evaporate the solvent in the adhesive or to initiate a thermosetting reaction; the other is ultraviolet curing, which is suitable for UV adhesives and uses ultraviolet light irradiation to initiate a rapid photopolymerization reaction. Regardless of the method, a cured reinforcement 400 that encapsulates and bonds the fibers is ultimately formed in the node area.

[0050] For heat-curing methods, the process parameters need to be set according to the adhesive formulation. Typically, the drying temperature is set between 60℃ and 180℃; too low a temperature will result in incomplete curing or a slow process, while too high a temperature may damage the fabric or degrade the adhesive layer's performance. The drying time is between 10 seconds and 10 minutes, and must be matched with the temperature, fabric thickness, and heat transfer efficiency. For UV curing, the key is to select a UV adhesive formulation suitable for the fiber material and provide a sufficiently strong UV light source to ensure that the UV light can effectively penetrate the surface fibers and induce deep curing of the adhesive layer.

[0051] The impregnation process can be achieved through various techniques to adapt to different node shapes and production cycle requirements, including but not limited to: dip coating, brush coating, spray coating, coating, and impregnation. These methods can be used individually or in combination. The adhesive material can be one or more of acrylic emulsions, polyurethane dispersions, two-component epoxy resins, and polyurethane adhesives.

[0052] S32: Hot-melt monolithic braiding heat treatment method S321: Weaving Introduction Stage. During the weaving of the three-dimensional fabric, the heat-melting monomer is introduced as an additional yarn system into a specific location on the fabric, namely the node area where the face structure 100, the middle yarn bundle 300, and the base structure 200 intersect, according to a pre-designed path and method. The introduction of the heat-melting monomer is carried out simultaneously with the weaving of other yarns, making it an integral part of the fabric structure. After being introduced into the fabric, the heat-melting monomer can be completely embedded inside the fabric or its end can protrude from the fabric surface, thus serving as a heat-melting target location. The protruding part is then melted onto the fabric surface after controlled heat treatment.

[0053] S322: Heat treatment melting stage. After the fabric is fully woven, it is placed in a heat treatment apparatus. Under controlled temperature conditions, the molten monomers woven into the node areas absorb heat, and at least a portion of their composition—it should be noted that for fused yarns, this is the entirety, and for core-sheath yarns, it is the sheath layer that melts, changing from a solid to a viscous flow state. Under the action of surface tension, capillary force, and possible pressure, the molten polymer material spreads along the fiber surface it contacts and penetrates into the tiny gaps inside the fiber bundle.

[0054] S323: Cooling and Curing Stage. After heat treatment, the fabric is removed from the thermal environment or actively cooled, such as by air cooling. The molten hot-melt polymer material cools and re-solidifies. During this process, it firmly bonds itself to all the fibers in the node area, ultimately forming a three-dimensional network-like integrated cured reinforcement 400 inside the node.

[0055] In stage S321, one basic preset method is linear weaving: the hot-melt monomer is woven through the node area in a straight line, just like ordinary weft or warp yarns. For example, when weaving a certain layer, a hot-melt yarn is inserted at a specific weft position. Another preset method that produces a better reinforcement effect is loop weaving. The specific operation is: at a specific moment in the weaving cycle, the yarn of the hot-melt monomer is guided to form a loop trajectory. This loop sequentially performs the actions of passing through the surface node, combining with the middle yarn bundle 300 in a looping or knotting manner, and then passing through the corresponding node of the bottom layer, and finally closing or self-locking the loop. In this way, a physical loop made of hot-melt material is pre-placed in the node space. In order to enhance the fabric's ability to resist oblique loads, when using the loop weaving method, the oblique loop weaving method is preferred. That is, when designing the path of the locking ring, it is made to form a significant angle with the axis of the middle filament 300 at the part connecting the surface weave 100 and the middle filament bundle 300, and / or at the part connecting the bottom weave 200 and the middle filament bundle 300, rather than being parallel or perpendicular. This makes the locking ring reinforce the aforementioned corner area. When this oblique locking ring melts and solidifies, the solidified reinforcement 400 formed in the corner area also has an oblique orientation, thereby more effectively transferring and converting the shear force on the surface layer or bottom layer into the axial force of the middle filament bundle 300 through the oblique reinforcement, greatly improving the shear stiffness and torsional stability of the node and even the entire fabric structure.

[0056] Regarding three-dimensional fabrics, the following explanation is provided: The reinforced three-dimensional fabric is achieved using double-needle-bed warp or weft knitting techniques, with its basic weaving steps relying on a collaborative knitting system. The core of this system includes a face structure 100 knitting mechanism, a base structure 200 knitting mechanism, and a middle yarn bundle 300 knitting mechanism. The face structure 100 knitting mechanism, composed of an upper needle bed, an upper sinker, and an upper yarn guide, is responsible for weaving the upper face structure 100. The base structure 200 knitting mechanism, composed of a lower needle bed, a lower sinker, and a lower yarn guide, is responsible for weaving the lower face structure 100. The middle yarn bundle 300 knitting mechanism is equipped with an independent yarn guide and control device, capable of reciprocating between the upper and lower needle beds, used to introduce and fix the middle yarn bundle 300 connecting the face and base layers. If a hot-melt monomer knitting reinforcement method is used, an additional independent hot-melt yarn guiding and tension control system is required to precisely introduce the hot-melt monomers into the node areas along a preset path during the weaving process.

[0057] Regarding the yarn system and raw materials, the face structure 100 and base structure 200 are typically made of synthetic fiber filaments or staple yarns such as polyester, nylon, or polypropylene, with a yarn fineness range, for example, from 150D to 500D. The middle tow 300 can be made of multifilaments or monofilaments with high modulus and good elastic recovery, such as high-elastic polyester, polypropylene, or glass fiber, with a fineness range, for example, from 300D to 1000D. If a hot-melt monomer is introduced, fully fused yarn, core-sheath yarn, or partially fused yarn can be selected, with a diameter, for example, between 0.05mm and 0.5mm, and a melting point at least 20°C lower than the softening point of the main yarn to ensure that the main structure is not damaged by heat during subsequent heat treatment.

[0058] Regarding the weaving process: In the loop-forming stage, the upper and lower needle beds rise synchronously to hook their respective yarns, while the middle yarn bundle 300 guide moves downward from the middle position, introducing the middle yarn bundle 300 into the lower needle bed area. Then, in the loop-breaking and connection stage, the upper and lower needle beds descend, and the yarn breaks off to form loops under the action of the sinker. The middle yarn bundle 300 is clamped and fixed between the upper and lower loops, forming an upright or inclined spatial connection structure. Next, in the drafting and warp-feeding stage, the fabric is drafted in both upward and downward directions to form a stable three-dimensional interval structure. Each yarn system is fed synchronously according to a preset warp-feed amount to maintain structural uniformity. If hot-melt monofilament weaving reinforcement is used, the hot-melt yarn also needs to be introduced into the intersection area of ​​the face structure 100, the middle yarn bundle 300, and the base structure 200 through an independent yarn guide along a preset path during the loop-forming or loop-breaking process. This introduction action can be performed synchronously or asynchronously with the middle yarn bundle 300 to form a linear, loop, or oblique reinforcement structure prototype.

[0059] Regarding structural parameter control, the density of the middle yarn bundle 300 is typically controlled at 5 to 12 yarns per square centimeter. The thickness of the face fabric 100 and the base fabric 200 can be adjusted between 0.2 mm and 2.0 mm. The total fabric thickness (i.e., the distance between the face layer and the base layer) can be set between 3 mm and 50 mm according to application requirements. The tilt angle of the middle yarn bundle 300 is generally maintained between 70° and 110°. In this process, the node area is defined as a three-dimensional spatial region with a radius of 1 mm to 5 mm centered on the intersection of the face fabric 100 and the middle yarn bundle 300. This region is the core location for subsequent reinforcement treatment.

[0060] Based on the design principles of the aforementioned reinforced three-dimensional fabrics and their two manufacturing methods, this section designs a compression fatigue test to verify its actual reinforcement effect: The compression fatigue test method was as follows: To fairly compare the durability of different three-dimensional fabrics, all samples underwent the same test: the fabric was cut into 10cm × 10cm specimens, and under normal humidity and room temperature conditions, it was repeatedly compressed to half its original thickness (50% strain) using a compression testing machine at a frequency of 2 cycles per second (2 Hz). The compression was paused every 200 cycles, and the presence of cracks in the cured reinforcement 400 at the nodes was observed using a 10x magnifying glass. The number of cycles at which the first visible crack appeared was recorded.

[0061] Experiment (1): Basic Three-Dimensional Fabric First, a basic three-dimensional spaced fabric sample with a thickness of 12 mm was prepared using conventional processes, with a face structure 100 and a base structure 200 made of 250D polyester filament and a middle bundle 300 made of 500D high-elastic polyester multifilament. The sample was then conditioned to a standard environment. Compression fatigue testing showed that after approximately 600 cycles, localized structural cracks appeared in the nodal areas due to yarn slippage and loosening of the interlacing points.

[0062] Experiment (2): External impregnation method for reinforcing fabrics A fabric greige was prepared using the same substrate and weaving parameters as the comparative example. Subsequently, the nodes where the face fabric 100, middle fiber bundle 300, and base fabric 200 intersect, as well as the middle fiber bundle 300, were impregnated with adhesive. A one-component polyurethane hot melt adhesive was used and cured at 80°C for 10 minutes, allowing the adhesive to encapsulate and bond the node fibers. In compression fatigue testing, after approximately 1000 cycles, localized cracks appeared at the interface between the cured adhesive coating and the fibers, particularly in corner areas and high stress concentration sites.

[0063] Experiment (3): Linear introduction of monofilaments to reinforce fabrics To verify the reinforcing effect of introducing the hot-melt monomer in a simple linear manner, this embodiment uses a 0.2 mm diameter fully meltable thermoplastic polyurethane (TPU) monofilament as the hot-melt monomer during the weaving of the three-dimensional fabric. This monofilament is alternately introduced as a weft yarn at corresponding node positions in the face structure 100 and the base structure 200. Specifically, during the weaving of each weft, a regular weft yarn is replaced with a TPU monofilament at predetermined face node 110 and base node 210 positions, allowing it to penetrate the node area. After weaving, the fabric is placed in a 140°C hot air circulating oven for 3 minutes to completely melt the TPU monofilament, allowing the melt to impregnate and coat the polyester fibers at the nodes. It is then naturally cooled to room temperature, forming a strip-shaped cured reinforcement 400 along the linear path.

[0064] In the compression fatigue test, after about 1300 cycles, microcracks appeared on the surface of the linearly cured reinforcement 400, but no overall detachment occurred.

[0065] Experiment (4): Longitudinal Locking Ring Reinforced Fabric To further enhance the vertical constraint and integrity of the nodes, this embodiment employs a longitudinal locking ring to introduce the hot-melt monomer. The selected hot-melt monomer is a core-sheath structure yarn, with a polyester core and an ethylene-vinyl acetate copolymer (EVA) sheath. During weaving, a dedicated yarn guiding device controls the hot-melt monomer to enter at the face node 110, then wrap around the center filament bundle 300 to form an O-ring, before exiting to the corresponding bottom node 210, with both ends of the ring self-interlaced and fixed outside the node. After weaving, a heat treatment at 155°C for 5 minutes is performed to melt the EVA sheath and impregnate the fibers within the surrounding area. After cooling, a longitudinal clamp-type cured reinforcement 400 is formed.

[0066] In the compression fatigue test, after about 1600 cycles, slight surface cracks appeared in the contact area between the locking ring and the middle wire bundle 300, but the overall structure remained intact and did not separate.

[0067] Experiment (5): Figure-eight lock ring reinforced fabric To simultaneously enhance the vertical support and shear-torsion resistance of the nodes, this embodiment employs a figure-eight locking ring structure, combined with an oblique arrangement to strengthen the corner area. The hot-melt monomer is selected as fully melt-type polyamide (PA) multifilament, which is controlled during weaving to pass sequentially through the face node 110, encircle the middle of the middle filament bundle 300 in a figure-eight shape, and then pass through the bottom node 210, with the rings crossing and self-locking within the node area. The entire structure is arranged at approximately a 45° angle to the middle filament bundle 300. The heat treatment conditions are 165°C for 4 minutes, allowing the PA to completely melt and penetrate into the fiber gaps, forming a spatial mesh reinforcement structure after cooling.

[0068] In the compression fatigue test, after about 1900 cycles, local microcracks appeared at the intersection of the locking rings, but the interface between the reinforcement and the fiber remained intact.

[0069] Experiment (6): In-situ reinforcement of fabrics with hot-melt monomers During the weaving process, a core-sheath structure of thermoplastic polyurethane is introduced, with a core layer of polyester and a sheath layer of thermoplastic polyurethane. This is woven into the nodes in a diagonal interlocking loop configuration to reinforce the corner area between the surface / bottom layer and the 300mm middle yarn bundle. After weaving, a heat treatment at 150℃ is performed to melt the sheath layer and impregnate the fibers, followed by cooling and solidification.

[0070] In the compression fatigue test, even after 2000 cycles, the solidified reinforcement 400 showed no cracks or interface separation, and the nodal area maintained its intact structure.

[0071] Overall Analysis and Conclusions: The reinforcement schemes in each experiment significantly improved the core mechanical properties and structural durability of the three-dimensional fabrics from different perspectives, effectively alleviating the problems of yarn slippage, plastic deformation, and fatigue failure caused by mechanical interweaving and friction in the node areas of the base fabric. This indicates that, regardless of whether external impregnation or internal hot-melt monomer weaving is used, physical or chemical reinforcement of the node areas is an effective way to improve the support, resilience, and shape stability of three-dimensional fabrics.

[0072] The in-situ reinforcement method using hot-melt monomers achieves intrinsic fusion between the reinforcement and the matrix by weaving the reinforcing material into the fabric structure, resulting in a strong interfacial bond and completely eliminating the risk of detachment. The linear introduction of monofilaments is the simplest process, has good compatibility with existing weaving systems, provides fundamental performance improvements, and is suitable for standardized, mass production. The longitudinal locking ring structure creates a strong, clamp-like constraint in the vertical direction, significantly improving the compressive stability and fatigue resistance of the nodes, making it suitable for applications requiring high vertical support. Furthermore, the combination of a diagonally arranged locking ring structure, by constructing spatial diagonal bracing or multi-directional mesh constraints in the corner area between the surface / bottom layer and the 300mm middle yarn bundle, endows the nodes with excellent shear resistance, torsion resistance, and multidimensional stability, achieving optimal levels in comprehensive indicators such as compressive strength, deformation recovery rate, and fatigue life.

[0073] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for weaving an enhanced three-dimensional fabric, characterized in that, Includes basic weaving steps and reinforcement treatment steps, The basic weaving steps include: The face weaving mechanism and the base weaving mechanism work together with hooks and sinkers to complete the looping, unlooping and drawing of the yarn, and weave the face weaving and base weaving respectively; The medium-tow weaving mechanism reciprocates between the surface weaving mechanism and the base weaving mechanism, simultaneously participating in the weaving of the surface and base structures, and forming upright medium-tows in between, thereby forming a three-dimensional fabric structure. The enhancement process includes: In the node region where the face structure, middle fiber bundle and base structure intersect, a cured reinforcement is formed in situ, and the cured reinforcement bonds the fibers in the node region.

2. The method for weaving the reinforced three-dimensional fabric according to claim 1, characterized in that, In the reinforcement process, the surface tissue, middle filament bundle and base tissue are impregnated with resin at least once in the node area where they intersect, and then cured by heating and drying or by UV curing to form a cured reinforcement.

3. The method for weaving the reinforced three-dimensional fabric according to claim 2, characterized in that, The impregnation method includes one or more of the following: dip coating, brush coating, spray coating, coating or impregnation.

4. The method for weaving the reinforced three-dimensional fabric according to claim 2, characterized in that, The adhesive material includes one or more of TPU, EVA, PVA, and PE.

5. The method for weaving the reinforced three-dimensional fabric according to claim 2, characterized in that, The heating and drying temperature is 60℃~180℃, and the drying time is 10 seconds to 10 minutes; The ultraviolet curing uses UV adhesive, which is cured by irradiation with an ultraviolet lamp.

6. The method for weaving the reinforced three-dimensional fabric according to claim 1, characterized in that, In the enhancement processing step The hot melt monomer is introduced into the node area where the face structure, middle yarn bundle and bottom structure intersect according to the preset weaving method through the hot melt monomer introduction mechanism; The woven fabric is heat-treated to melt at least part of the hot melt monomer, and the melt flows and wets the fiber surface and gaps in the node region. Cooling and curing are performed to form an integrated cured reinforcement in the node region.

7. The method for weaving the reinforced three-dimensional fabric according to claim 6, characterized in that: The preset weaving method is as follows: the hot melt monomer is woven into the fabric in the form of linear yarn.

8. The method for weaving the reinforced three-dimensional fabric according to claim 6, characterized in that: The preset weaving method is as follows: the hot melt monomer is woven into the fabric in the form of a lock ring, the lock ring passes through the surface node, surrounds or interweaves the middle yarn bundle, and then passes through the corresponding node of the bottom layer.

9. The method for weaving the reinforced three-dimensional fabric according to claim 6, characterized in that: The preset weaving method is as follows: the hot melt monomer is woven into the fabric at an angle inclined relative to the middle yarn bundle, and the hot melt monomer is connected to the corner area between the face fabric and / or the base fabric and the middle yarn bundle.

10. The method for weaving the reinforced three-dimensional fabric according to claim 6, characterized in that: The hot-melt monomer is introduced by weft insertion, warp insertion, or knitting, and forms a cross, wrap, or knot structure with the yarns of the face or base structure in the node area.

11. The method for weaving the reinforced three-dimensional fabric according to claim 6, characterized in that: The hot-melt monomer is one of a fully fused wire, a core-sheath structured wire, or a partially fused wire; The core-sheath structure includes a core layer and a hot-melt material outer layer covering the core layer.

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