Warp-knitted integrated pile fabric and preparation method therefor

Abstract

The present invention relates to the technical field of pile fabrics and the preparation thereof, and in particular to a warp-knitted integrated pile fabric and a preparation method therefor. The pile fabric comprises a first pile layer, a second pile layer, and a connecting layer located between the first pile layer and the pile layer, wherein the first pile layer comprises a front guide bar laid-in yarn layer formed by processing laid-in yarn of a front guide bar; the connecting layer sequentially comprises, from the first pile layer to the second pile layer, a middle guide bar laid-in yarn layer, a back guide bar laid-in yarn layer, a middle guide bar loop layer and a front guide bar loop layer, which are sequentially and respectively formed by interlacing laid-in yarns of a middle guide bar, laid-in yarns of a back guide bar, loops of the middle guide bar and loops of the front guide bar; and the second pile layer comprises a back guide bar loop layer, a back guide bar laid-in yarn layer, or a combination layer thereof. The preparation method comprises yarn warping, on-machine knitting, and dyeing and finishing. The present invention can form a variety of structures, and the types and colors of pile on the front and back sides can be independently selected and freely combined on the basis of a design and requirements, thereby forming a variety of style effects.

Description

Warp-knitted one-piece plush fabric and preparation method thereof TECHNICAL FIELD

[0001] The present application relates to the technical field of plush fabric and its preparation, in particular to a warp-knitted one-piece plush fabric and a preparation method thereof. BACKGROUND

[0002] With the development of society and the progress of technology, people's requirements for the quality of fabrics used in clothing and home textiles are also getting higher and higher. As a major category of autumn and winter clothing and home textile products, plush products are rich in variety and widely used. People not only satisfy the appearance, comfort, warmth and other aspects of plush products, but also pay more and more attention to their environmental protection, diversity and use safety.

[0003] In recent years, "one-piece plush" has emerged in the market and become popular. The so-called "one-piece plush" mainly refers to double-sided plush that can be directly combined without the need for compounding, also known as "compound-free" plush. Since no compounding process is required, the use of chemical substances such as glue is avoided, and the problem of separation of the two sides of the fabric caused by the glue easily peeling off during use is also avoided, thereby improving the use safety and durability of the product. Most of the one-piece plushes on the market are basically weft-knitted structures. For example, patent CN 112593336 A introduces a fur and leather one-piece fabric and its production process, which is made of a weft-knitting double-sided machine structure. The front side of the fur and leather one-piece fabric is made of 222 dtex / 96F polyester filament, and the back side is made of 21 SJC, the intermediate connecting yarn uses 83 dtex / 36F polyester filament, and then a conventional woolen dyeing and finishing process is used to form a double-sided integrated fabric with one side being a cotton plain fabric structure and the other side being a polyester woolen fabric structure. Since a weft-knitting double-sided machine is used, the machine itself can weave different weft-knitted fabrics on both sides, but the weaving efficiency is very low, and the weft-knitted structure is easy to fall apart. The connection between the two sides is only by a single polyester filament, and the connection strength between the two sides is not high. In addition, the structure of one side being a plain fabric and the other side being a woolen fabric is also very limited. For example, patent CN 114737305 A proposes an integrated cut-loop pile fabric, which includes a knitted structure and a plurality of yarn groups woven into the knitted structure. The yarn group includes a base yarn and a pile yarn forming a loop on one side of the knitted structure. The base yarn holds the pile yarn, and the loop is cut to form a cut-loop pile. From the structural essence, it still belongs to a weft-knitted cut-loop pile product, and still has the problems of low weaving efficiency, easy structure falling apart, and loose weft-knitted structure. It is difficult to avoid the problem of pile shedding by relying on the base yarn (or called "binding yarn") to hold the pile yarn. In addition, this kind of fabric structure is relatively fixed, lacks flexibility, and it is difficult to realize wide or even super-wide width to meet the needs of home textile use. For example, patent CN 107460619 A discloses a short-pile flannel production method, which pulls the woolen part of the front side of the warp-knitted single-sided flannel to the back side to form a double-sided woolen fabric. In this way, the material, pile height, and style of the woolen fabric on the back side can only depend on the woolen fabric on the front side, resulting in single and similar woolen feeling on the front and back sides, lack of creativity, and the process of pulling the woolen fabric on the front side to the back side reduces the fullness of the woolen fabric on the front side. Moreover, the process of pulling the woolen fabric can damage the loop structure and root fibers of the woolen fabric on the front side, causing the problem of pile shedding.

[0004] Therefore, there is an urgent need for a warp-knitted integrated pile fabric and a preparation method thereof, which has high weaving production efficiency, large and varied differences in woolen style between the front and back sides, small limitations, stable structure, and no pile shedding, without the need for compounding, safety, environmental protection, durability, and suitability for clothing, home textile, and other uses.

[0005] The existing pile fabric has the following technical problems:

[0006] 1. The weft-knitted integrated pile fabric has a relatively single structure, weak variation between the front and back sides, unstable structure, easy falling apart and pile shedding, and the need for special cut-loop pile machines for production, low production efficiency, and difficulty in meeting the needs of wide or even super-wide width.

[0007] 2. Due to the inherent structural limitations of warp-knitted plush products, the plush on the front and the base fabric on the back are made of the same yarn. Moreover, the back cannot be used directly and needs to be laminated or napped. For napping, the plush portion on the front (about 40%) is pulled to the back. In essence, the material, pile height, and style of the plush on the back can only depend on the plush on the front. The plush on the front and back affect each other and cannot be formed or processed independently. This results in a monotonous and similar plush feel on both sides of the fabric, lacking creativity. It also reduces the fullness of the plush on the front. Furthermore, during the process of pulling the plush from the front to the back, it passes through the base fabric, which will cause damage to the fabric structure and fibers, thereby exacerbating shedding. Summary of the Invention

[0008] To solve the aforementioned technical problems, the present invention provides a warp-knitted integrated fleece fabric, comprising a first fleece layer, a second fleece layer, and a connecting layer located between the first fleece layer and the second fleece layer.

[0009] The first plush layer includes a front comb extension layer, which is formed by processing the extension lines of the front comb;

[0010] The connecting layer, from the first plush layer to the second plush layer, includes a middle comb extension line layer, a back comb extension line layer, a middle comb coil layer, and a front comb coil layer. Each layer is formed by the interlacing of the middle comb extension line, the back comb extension line, the middle comb coil, and the front comb coil.

[0011] The second plush layer includes a back comb coil layer, a back comb extension line layer, or a combination of both. The back comb coil layer is formed by processing back comb coils, the back comb extension line layer is formed by processing back comb extension lines, and the combination layer is formed by processing back comb coils and extension lines.

[0012] Optionally, the front comb adopts an N+1 needle closed warp plain weave, and the padding yarn is denoted as: 1-0 / N-(N+1) / / (N≥15);

[0013] or,

[0014] The front comb uses two N+1 needles and P+1 needles in the same direction, closed warp plain weave, and the padding yarn numbers are recorded as: 1-0 / N-(N+1) / / (N≥15) and 1-0 / P-(P+1) / / (P≤10).

[0015] Optionally, the center comb uses an L+1 needle closed warp plain weave, and the padding yarn is denoted as: L-(L+1) / 1-0 / / (1≤L≤3);

[0016] or,

[0017] The middle comb adopts two reverse L+1 needle closed plain knits, and the inlaying number codes are respectively recorded as: L-(L+1) / 1-0 / / (1≤L≤3) and 1-0 / L-(L+1) / / (1≤L≤3).

[0018] Optionally, the back comb adopts M+1 needle open plain knits, and the inlaying number code is recorded as: 0-1 / (M+1)-M / / (2≤M≤5).

[0019] Alternatively,

[0020] The back comb adopts M needle weft insertion knits, and the inlaying number code is recorded as: M-M / 0-0 / / (2≤M≤5).

[0021] Alternatively,

[0022] The back comb adopts M+1 needle open plain knits, and the inlaying number code is recorded as: (M+1)-M / 0-1 / / (2≤M≤5).

[0023] Alternatively,

[0024] The back comb adopts two reverse M+1 needle open plain knits, and the inlaying number codes are respectively recorded as: 0-1 / (M+1)-M / / (2≤M≤5) and (M+1)-M / 0-1 / / (2≤M≤5), or the back comb adopts two reverse M needle weft insertion knits, and the inlaying number codes are respectively recorded as: 0-0 / M-M / / (2≤M≤5) and M-M / 0-0 / / (2≤M≤5), or the back comb adopts one M+1 needle open plain knit and one M needle weft insertion knit, and the inlaying number codes are respectively recorded as: 0-1 / (M+1)-M / / and 0-0 / M-M / / (2≤M≤5).

[0025] Optionally, the front comb selects 75-300D polyester DTY round hole low-elasticity filament, and the single filament fineness range is 0.52-1.04D, or 75-300D polyester FDY flat section filament, and the single filament fineness range is 1.04-4.16D.

[0026] The middle comb selects 50-100D polyester FDY or DTY ordinary polyester filament, and the actual let-off amount of the middle comb is 0.85-0.95 times of the calculated let-off amount.

[0027] The back comb selects 75-300D polyester DTY round hole low-elasticity filament, and the single filament fineness range is 0.52-1.04D, or selects one of 75-300D polyester sea island filament, original liquid colored polyester filament, lyocell filament and mulberry silk, and the actual let-off amount of the back comb is 1.5-3 times of the calculated let-off amount.

[0028] The application also provides a preparation method of the warp-knitted integrated pile fabric.

[0029] S100: Determine the knitting yarn raw material, and use the selected warper to warp the yarn;

[0030] S200: Use the warp knitting machine configured with not less than three guide bars to divide the guide bars into three groups for front, middle and back knitting, and perform on-machine knitting;

[0031] A. Lacing: front guide bar: 1 in 1 out; middle guide bar: full threading; back guide bar: full threading;

[0032] B. Knitting: perform the knitting process according to the following let-off amount:

[0033] Front guide bar: the let-off amount is 0.9-1.1 times the calculated let-off amount;

[0034] Middle guide bar: the let-off amount is 0.85-0.95 times the calculated let-off amount;

[0035] Back guide bar: the let-off amount is 1.5-3 times the calculated let-off amount;

[0036] The pulling density used in knitting is in the range of 13-20 cpc, and the starting speed is in the range of 1500-2200 rpm;

[0037] S300: Perform dyeing and finishing processing on the obtained gray cloth to obtain the warp-knitted integrated pile fabric.

[0038] Optionally, in the step S200, before on-machine knitting, the back guide bar tension compensation device is adjusted, i.e. the tension rod of the back guide bar tension compensation device is extended forward by 15-35 cm; and the back guide bar tension compensation device uses a tension spring with a tension sensitivity of not less than 0.1 cN.

[0039] Optionally, in the step S100, the yarn warping method is as follows:

[0040] Front guide bar: SGZ400D intelligent computer-controlled warper is used, the disc head specification is Φ21x21", the warping head number is 293, the warping disc head number is 8, the warping speed is 1200 rpm, and the warping tension is 8-9 cN;

[0041] Middle guide bar: SGZ300D computer-controlled high-speed warper is used, the disc head specification is Φ21x21", the warping head number is 588, the warping disc head number is 8, the warping speed is 1500 rpm, and the warping tension is 5-6 cN;

[0042] Back combing: SGZ400D intelligent computer controlled warper is adopted, disc head specification: Φ21*21"; warping head number: 588; warping disc head number: 8; warping speed: 1200rpm; warping tension: 8-9cN.

[0043] Optionally, in the step S300, the dyeing and finishing process comprises:

[0044] The second pile layer side is sequentially subjected to fabric back pre-setting, back pulling or milling, and back shearing;

[0045] The first pile layer side is sequentially subjected to fabric front pre-setting, front pulling, and front glazing;

[0046] The first pile layer side and the second pile layer side after the front processing are sequentially subjected to dyeing, softening, drying, and hot blowing; then the first pile layer side is subjected to front shearing, and the second pile layer side is subjected to back shearing; finally, the fabric is subjected to grain processing and fabric rolling.

[0047] Optionally, during the weaving process, a CCD camera is used to capture images of yarn feeding, and a weaving machine vibration is detected;

[0048] Each single yarn is distinguished through image recognition, and vibration transmission simulation analysis of each single yarn is performed using simulation technology according to the feeding distance of each single yarn and the detected weaving machine vibration data, to obtain vibration data of each point in the feeding distance of each single yarn; the vibration data includes vibration amplitude;

[0049] Machine vision recognition technology is used to pre-process the captured real-time images, each single yarn is distinguished through image recognition, and image analysis of each single yarn is performed in combination with the vibration data of the corresponding single yarn, to obtain the diameter data of each point of the real-time feeding single yarn;

[0050] The diameter data is compared with the upper and lower threshold values of the diameter of the corresponding single yarn, and if the diameter data deviates from the diameter range defined by the upper and lower threshold values, an alarm information is issued.

[0051] The warp-knitted integrated pile fabric and the preparation method thereof can be diversified and combined to realize the differential appearance effect of "hair" on the front side and "pile" on the back side. The two sides can be independent of each other and do not affect each other. In combination with the selection of yarn raw materials and the adjustment of post-finishing process, the possibility of various style changes can be extended. For example, the front side can form appearance effects of A imitated rabbit hair, B imitated mink hair, C imitated sheep hair, D milk pile, E arctic pile, and the back side can form appearance effects of V imitated suede, W imitated shake pile, X imitated O pile, Y imitated corduroy, and Z imitated cashmere pile. A to E and V to Z can be randomly and arbitrarily combined to form various change structures. Meanwhile, the respective colors of the front side and the back side can be independently selected and freely combined to form many style effects from the color. Unlike the traditional fabric structure, the front and back effects are not similar and lack of creativity.

[0052] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent from the description, or can be learned by practice of the present application. The objects and other advantages of the present application will be realized and attained by the structure particularly pointed out in the written description and claims hereof.

[0053] The technical solutions of the present application will be further described in detail below with the help of the accompanying drawings and examples. BRIEF DESCRIPTION OF DRAWINGS

[0054] The accompanying drawings are included to provide a further understanding of the present application, and constitute a part of the specification, illustrate the present application and explain the principles of the present application, and do not constitute a limitation of the present application. In the drawings:

[0055] Fig. 1 is a schematic diagram of a cross-sectional structure of a warp-knitted integrated pile fabric in an embodiment of the present application;

[0056] Fig. 2 is a schematic diagram of a knitting structure of a warp-knitted integrated pile fabric in an embodiment of the present application;

[0057] Fig. 3 is a schematic diagram of a process flow of a preparation method of a warp-knitted integrated pile fabric in an embodiment of the present application;

[0058] Fig. 4 is a schematic diagram of an application case flow of a preparation method of a warp-knitted integrated pile fabric in an embodiment of the present application;

[0059] Fig. 5 is a schematic diagram of a shape of an application case of a preparation method of a warp-knitted integrated pile fabric in an embodiment of the present application in the process of on-machine knitting;

[0060] Fig. 6 is a schematic diagram of a shape of an application case of a preparation method of a warp-knitted integrated pile fabric in an embodiment of the present application in the process of dyeing and finishing. DETAILED DESCRIPTION

[0061] The preferred embodiments of the present application are described below in conjunction with the accompanying drawings, in which it is understood that the preferred embodiments described herein are merely intended to illustrate and explain the present application, and are not intended to limit the present application.

[0062] As shown in FIGS. 1-2, the embodiment of the present application provides a warp-knitted integrated pile fabric, which comprises a first pile layer 1 and a second pile layer 3 and a connecting layer 2 between the first pile layer 1 and the second pile layer 3.

[0063] The first pile layer 1 comprises a front comb extended thread layer, which is formed by using the extended thread of the front comb.

[0064] The connecting layer 2 comprises, in sequence from the first pile layer 1 to the second pile layer 3, a middle comb extended thread layer 21, a back comb extended thread layer 22, a middle comb loop layer 23 and a front comb loop layer 24, which are formed by using the extended thread of the middle comb, the extended thread of the back comb, the loop of the middle comb and the loop of the front comb, respectively.

[0065] The second pile layer 3 comprises a back comb loop layer, a back comb extended thread layer or a combination layer of the two, wherein the back comb loop layer is formed by using the loop of the back comb, the back comb extended thread layer is formed by using the extended thread of the back comb, and the combination layer is formed by using the loop and the extended thread of the back comb.

[0066] The working principle and beneficial effects of the technical scheme are as follows: the warp-knitted integrated pile fabric can be knitted by a three-needle ordinary tricot warp-knitting machine or a four-needle ordinary tricot warp-knitting machine, and the structure of the warp-knitted integrated pile fabric includes a first pile system (i.e., a first pile layer) on the front side, a second pile system (i.e., a second pile layer) on the back side, and a connecting system (i.e., a connecting layer) in the middle. The warp-knitted integrated pile fabric is knitted by at least one front needle, one back needle, and one middle needle. The first pile system is formed by processing the extended wire of the front needle, and the second pile layer can include a back needle loop layer or a (partial) back needle extended wire layer. The second pile layer can also be a combined layer of the back needle loop layer and the back needle extended wire layer, i.e., the following cases are specifically unfolded: a. the back needle is one needle (looping), which forms the back needle loop layer; b. the back needle is one needle (weft insertion), which forms the (partial) back needle extended wire layer; c. the back needle is two needles, and both needles are looping, which forms the back needle loop layer; d. the back needle is two needles, and both needles are weft insertion, which only has extended wire without loop, and both needles form the (partial) back needle extended wire layer; e. the back needle is two needles, one is weft insertion, and the other is looping, which forms the (partial) back needle extended wire layer and the back needle loop layer by using the loop or partial extended wire of the back needle. The first pile system and the second pile system are independent of each other and do not affect each other. The cross-sectional structure of the warp-knitted integrated pile fabric during knitting includes at least six levels from the front side to the back side, i.e., front needle extended wire, middle needle extended wire, back needle extended wire, middle needle loop, front needle loop, and back needle loop. The relative level position relationship of the cross-sectional structure of the integrated pile is maintained unchanged during subsequent processing. The warp-knitted pile structure breaks through the inherent pile structure (the cross-sectional structure from the front side to the back side is front needle extended wire, middle needle extended wire, back needle extended wire, back needle loop, middle needle loop, and front needle loop, i.e., the back needle is clamped in the core layer and is "clamped" by the extended wire and loop layers of the middle needle and the front needle) of the traditional warp-knitting process, realizes innovative changes in the relative positions and level relationships of the front needle, the middle needle, and the back needle of the pile fabric, and further establishes the structural basis for forming the warp-knitted integrated pile.The tricot integrated pile fabric of the scheme can be diversified combined to realize the differential appearance effect of "hair" on the front and "pile" on the back. The styles of the two sides can be independent of each other and do not affect each other. In combination with the selection of yarn raw materials and the adjustment of post-finishing process, the possibility of a variety of style changes can be extended. For example, the front can form appearance effects of A imitated rabbit hair, B imitated mink hair, C imitated sheep hair, D milk pile, E arctic pile, etc. The back can form appearance effects of V imitated suede, W imitated shake pile, X imitated O pile, Y imitated corduroy, Z imitated cashmere pile, etc. A-E and V-Z can be randomly and arbitrarily combined to form a variety of change structures. Meanwhile, the respective colors of the front and back pile systems can also be independently selected and freely combined to form many style effects from the color. Unlike the traditional fabric structure, the front and back effects are not similar and lack of creativity.

[0067] In one embodiment, the front comb adopts N+1 needle closed warp plain stitch, and the inlay number code is 1-0 / N-(N+1) / / (N is a positive integer, and N≥15). For example, the inlay number code is 1-0 / 17-18 / / .

[0068] Alternatively,

[0069] The front comb adopts two N+1 needle and P+1 needle closed warp plain stitches in the same direction, and the inlay number codes are 1-0 / N-(N+1) / / (N≥15) and 1-0 / P-(P+1) / / (P≤10) respectively.

[0070] The working principle and beneficial effects of the above technical scheme are that by further limiting the knitting structure form (warp plain stitch) of the front comb, the operability and guidance in the production process are enhanced for the production of the pile fabric product, which is conducive to the standardization of production, the quality control and management of products, and the improvement of production efficiency.

[0071] In one embodiment, the middle comb adopts L+1 needle closed warp plain stitch, and the inlay number code is L-(L+1) / 1-0 / / (1≤L≤3). For example, the inlay number code is 1-2- / 1-0 / / .

[0072] Alternatively,

[0073] The middle comb adopts two L+1 needle closed warp plain stitches in opposite directions, and the inlay number codes are L-(L+1) / 1-0 / / (1≤L≤3) and 1-0 / L-(L+1) / / (1≤L≤3) respectively.

[0074] The working principle and beneficial effects of the above technical scheme are that by further limiting the knitting structure form (warp plain stitch) of the middle comb, the operability and guidance in the production process are enhanced for the production of the pile fabric product, which is conducive to the standardization of production, the quality control and management of products, and the improvement of production efficiency.

[0075] In one embodiment, the back comb adopts M+1 needle open plain weave, and the number of the padding is coded as: 0-1 / (M+1)-M / / (2≤M≤5); for example, the padding number is 0-1 / 4-3 / / .

[0076] Alternatively,

[0077] The back comb adopts M needle weft insertion, and the number of the padding is coded as: M-M / 0-0 / / (2≤M≤5);

[0078] Alternatively,

[0079] The back comb adopts M+1 needle open plain weave, and the number of the padding is coded as: (M+1)-M / 0-1 / / (2≤M≤5);

[0080] Alternatively,

[0081] The back comb adopts two sets of reverse M+1 needle open plain weave, and the numbers of the padding are coded as: 0-1 / (M+1)-M / / (2≤M≤5) and (M+1)-M / 0-1 / / (2≤M≤5) respectively, or the back comb adopts two sets of reverse M needle weft insertion, and the numbers of the padding are coded as: 0-0 / M-M / / (2≤M≤5) and M-M / 0-0 / / (2≤M≤5) respectively, or the back comb adopts one set of M+1 needle open plain weave and one set of M needle weft insertion, and the numbers of the padding are coded as: 0-1 / (M+1)-M / / and 0-0 / M-M / / (2≤M≤5) respectively.

[0082] The working principle and beneficial effects of the above technical solutions are as follows: the present scheme further limits the weaving structure form (plain weave or weft insertion) of the back comb, and the actual structure is not limited to the above structure, and the weaving process and structure are adjusted on this basis, such as changing the loop structure to weft insertion, changing the open loop to closed loop, changing the M needle value range, etc., which should be considered within the protection scope of the present technical invention; for the production of pile fabric products, the operability and guidance in the production process are enhanced, which is beneficial to the standardization of production, the quality control and management of products, and the improvement of production efficiency.

[0083] In one embodiment, the front comb selects 75-300D polyester DTY round hole low-elasticity filament, and the single filament fineness range is 0.52-1.04D, or 75-300D polyester FDY flat section filament, and the single filament fineness range is 1.04-4.16D; wherein, D is the fineness unit "denier" or "denier" (i.e. Denier, denier);

[0084] The middle comb selects 50-100D polyester FDY or DTY ordinary polyester filament, and the actual let-off amount of the middle comb is 0.85-0.95 times the calculated let-off amount;

[0085] The back combing uses 75-300D polyester DTY round hole low elastic filament, and the single filament fineness range is 0.52-1.04D; or one of 75-300D polyester sea-island filament, dope-dyed polyester filament, lyocell filament and mulberry silk, and the actual let-off amount of the back combing is 1.5-3 times of the calculated let-off amount.

[0086] The working principle and beneficial effects of the technical solution are as follows: the yarn raw material and feeding parameters (let-off amount) adopted in the scheme are further limited, the operability and guidance in the production process of the pile fabric product are enhanced, the standardization of production is beneficial, the quality control and management of the product are beneficial, and the production efficiency is improved; wherein the let-off amount refers to the length of the warp yarn (generally in mm) for sending out 480 courses of loops (including loops and extension lines), the let-off amount is related to factors such as the model of the machine, the weave, and the longitudinal density of the loops, the calculated let-off amount can be obtained by theoretical calculation, and the actual let-off amount generally used in the prior art does not deviate much from the calculated let-off amount, the calculated let-off amount is also called the theoretical let-off amount, which is obtained according to theoretical calculation, and the theoretical let-off amount is usually input into the warp knitting machine by the operator for debugging the machine; before knitting, the let-off amount is adjusted according to the actual knitting situation, but the adjustment is usually within a small range, that is, the deviation from the theoretical let-off amount is not more than ±10%; in the scheme, the actual let-off amount of the combing is selected to be less than the calculated let-off amount, and the actual let-off amount of the back combing is selected to be much greater than the calculated let-off amount, so that the structure optimization and process refinement are further realized on the basis of the pile fabric structure, that is, the process (weave, laying process, loop opening / closing form, let-off amount relationship, and other structure parameters) of the front, middle, and back combing is limited and protected.

[0087] As shown in FIG. 2, the present application also provides a preparation method of the aforementioned warp-knitted integrated pile fabric, comprising the following steps:

[0088] S100: determining the knitting yarn raw material, and performing yarn warping by using the selected warper;

[0089] S200: using a warp knitting machine configured with not less than three guide bars to divide the guide bars into three groups respectively responsible for the knitting of the front combing, the middle combing, and the back combing, and performing on-machine knitting:

[0090] For example: using a common tricot warp knitting machine (gauge: E28) configured with not less than three guide bars (for example, three or four), dividing the guide bars into three groups respectively responsible for the knitting of the front combing, the middle combing, and the back combing, for example, if there are four guide bars, one group of two guide bars is responsible for the front combing, the middle combing, and the back combing; the machine door width of the warp knitting machine is 210 inches;

[0091] A. threading: the front combing GB1: 1 threading 1 empty; the middle combing GB2: full threading; the back combing GB3: full threading;

[0092] B. Weaving:

[0093] The weaving process is as follows

[0094] Front comb GB1: the actual let-off amount used is 0.9-1.1 times the calculated let-off amount; for example, the calculated let-off amount is 8350 mm / rack, and the actual let-off amount is 8360 mm / rack;

[0095] Middle comb GB2: the actual let-off amount used is 0.85-0.95 times the calculated let-off amount; for example, the calculated let-off amount is 1360 mm / rack, and the actual let-off amount is 1200 mm / rack;

[0096] Back comb GB3: the actual let-off amount used is 1.5-3 times the calculated let-off amount; for example, the calculated let-off amount is 2230 mm / rack, and the actual let-off amount is 4200 mm / rack;

[0097] The drawing density used in weaving is in the range of 13-20 cpc, for example, the drawing density used in weaving can be 16.5 cpc, and the machine speed is in the range of 1500-2200 rpm; for example, the machine speed can be 1800 rpm; that is, the drawing density and the machine speed are a fixed value, and both of them need to be set in advance on the machine when the machine is actually started to weave;

[0098] S300: dyeing and finishing processing is performed on the woven fabric obtained in the step S200, to obtain the warp-knitted integrated fleece fabric.

[0099] The working principle and beneficial effects of the technical solution are as follows: the preparation method of the warp-knitted integrated pile fabric can realize diversified combination, realize the differential appearance effect of the "hair" on the front side and the "pile" on the back side, and the styles of the two sides can be independent of each other and do not affect each other. In combination with the selection of yarn raw materials and the adjustment of post-finishing process, the possibility of various style changes can be extended, for example, the front side can form appearance effects of A imitated rabbit hair, B imitated mink hair, C imitated sheep hair, D milk pile, E arctic pile, and the back side can form appearance effects of V imitated suede, W imitated shake pile, X imitated O pile, Y imitated corduroy, and Z imitated cashmere pile. A-E and V-Z can be randomly and arbitrarily combined to form various change structures. Meanwhile, the respective colors of the front and back pile systems can also be independently selected and freely combined, and many style effects can also be formed in terms of color. Unlike the traditional fabric structure, the front and back effects are not similar, and the lack of creativity is avoided. On the basis of the pile fabric structure, the structure optimization and process refinement are further protected, that is, the process of the front, middle and back combs (knitting organization, padding process, loop opening / closing form, and structure parameters such as let-off amount relationship) is limited and protected, especially the process details of the back comb are protected. Specifically, during the weaving of the gray fabric, the process details of the back comb can be protected by adjusting the tension compensation device.

[0100] During the weaving process, the yarn shapes of the front comb, the middle comb and the back comb are shown in FIG. 5. The dot matrix is used to form a positioning grid to assist understanding. The front comb forms a closed warp plain organization spanning 18 needles, the middle comb forms a closed warp plain organization spanning 2 needles, and the back comb forms an open warp plain organization spanning 4 needles. Moreover, the back comb is woven into the gray fabric in a relaxed and bent state during the weaving process, forming a "stored" effect (similar to the state of a compression spring).

[0101] In one embodiment, before weaving in the S200 step, the back comb tension compensation device is adjusted, that is, the tension rod of the back comb tension compensation device is extended forward by 15-35 cm; and the back comb tension compensation device uses a tension spring with a tension sensitivity of not less than 0.1 cN.

[0102] The working principle and beneficial effects of the above technical solution are: during the weaving of the grey cloth, the tension compensation device is adjusted, the tension rod is extended 15-35 cm in front of the machine, at the same time, the tension spring is replaced by one with high precision and sensitivity (small tension fluctuation is also sensitive, and the tension sensitivity is not less than 0.1 cN), so as to compensate the tension adjustment in the "over-relaxed" state in time, and then stabilize and uniform the yarn tension, and prevent the back combing yarn from "floating" uncontrollably. For the excess let-off amount of the back combing, the extension line is woven into the grey cloth in a loose and bent state during weaving, and is "stored" (similar to the state of a compression spring). When the back processing is performed, part of the extension line (50-200% of the excess let-off amount) is converted into a loop and is elongated, similar to a spring being stretched, and the loop is "pushed out". Thus, during the weaving of the grey cloth, the process details of the back combing are protected by adjusting the tension compensation device. The relationship between the loop height of the back combing loop (back loop) and the let-off amount is as follows: H = [(R-R0) ÷ 480-1.43d] ÷ 2 x η

[0103] wherein,

[0104] H: loop height of the back combing loop (back loop), unit: mm; one back combing loop can be approximately regarded as one semicircular arc + two loop columns, and the loop column height is H, which corresponds to the conversion coefficient value. The loop height of the back combing loop (back loop) obtained by calculation according to the above formula is in the range of 1.6-2.0 mm; in fact, the loop height of the back loop in the range of 1.5-6.0 mm is also acceptable;

[0105] R: actual let-off amount of the back combing; unit: mm / 480 courses;

[0106] R0: calculated let-off amount of the back combing; unit: mm / 480 courses;

[0107] d: needle thickness, unit: mm;

[0108] η: conversion coefficient (i.e. conversion of the back combing extension line into the back combing loop), which is set by machine adjustment in the range of 80-99%.

[0109] In one embodiment, in the S100 step,

[0110] The yarn raw material can be selected as follows:

[0111] The front combing selects 75D / 72F wavy flat section super-dull polyester FDY filament;

[0112] Middle comb selects 45D / 24F round hole section semi-dull polyester FDY filament;

[0113] Back comb selects 75D / 144DF round hole section full-dull polyester DTY filament.

[0114] The working principle and beneficial effects of the above technical solution are that:

[0115] The yarn warping method is as follows:

[0116] Front comb: SGZ400D intelligent computer-controlled warping machine is adopted, the disc head specification is Φ21*21" (inch), the warping head number is 293, the warping disc head number is 8, the warping speed is 1200 rpm, and the warping tension is 8-9 cN;

[0117] Middle comb: SGZ300D computer-controlled high-speed warping machine is adopted, the disc head specification is Φ21*21", the warping head number is 588, the warping disc head number is 8, the warping speed is 1500 rpm, and the warping tension is 5-6 cN;

[0118] Back comb: SGZ400D intelligent computer-controlled warping machine is adopted, the disc head specification is Φ21*21", the warping head number is 588, the warping disc head number is 8, the warping speed is 1200 rpm, and the warping tension is 8-9 cN.

[0119] The working principle and beneficial effects of the above technical solution are that: the yarn raw material, equipment operation parameters, feeding parameters (warping amount) adopted in the scheme are further limited, the operability and guidance in the production process are enhanced for the production of the suede fabric product, which is conducive to the standardization of production, the quality control and management of products, and the improvement of production efficiency.

[0120] In one embodiment, as shown in FIG. 4, in the S300 step, the dyeing and finishing process includes:

[0121] The second pile layer side (referring to this side of the second pile layer, i.e. the back) is sequentially subjected to gray cloth back pre-setting, back pulling or sanding, and back shearing; the gray cloth back pre-setting is to pre-set the gray cloth back upward (temperature 180-190℃, for example, the temperature is 185℃, and the speed is 20-25 m / mim), so that the gray cloth obtains stable size and structural morphology; the pulling uses 48 roll*2 and 60 roll*2 pulling machine, and four joint rollers continuously pull the gray cloth back to obtain short and uniform pile;

[0122] The first pile layer side (referring to this side of the first pile layer, i.e., the front) is sequentially processed with the fabric front pre-forming, front napping, and front calendering. The fabric front pre-forming is performed with the fabric face up (temperature 215℃, machine speed 20m / min) to give the fabric a certain stiffness. The front napping uses a 24-roller×2 and 36-roller×2 napping machine, with four rollers continuously raising the nap on the fabric front to obtain long and uniform nap. The front calendering conditions are: temperature 170~180℃, machine speed 15-20m / min.

[0123] The first and second pile layers, after previous processing, are sequentially dyed, washed, softened, dried, and hot-blown. For greige fabric dyeing and white greige dyeing (yarn-dyed greige fabric does not require dyeing), a high-temperature, high-pressure liquid flow dyeing machine is used, employing disperse dyes in an environment with a pH of 6–7. The heating rate is 1.5℃ / min, the holding temperature is 120–130℃, the holding time is 30–45 min, and the cooling rate is 1.8℃ / min. Dyeing can achieve alkali reduction. Washing... Softening: Softening is performed using a roller mill. Softener and smoothing agent are mixed with grade III water at a concentration of 30-60 g / L and injected into the roller mill. A two-dip, two-roll process is used, with the softening speed controlled at 5-15 m / min. After softening, the fabric is dehydrated. Drying: The setting machine temperature is set to 160-170℃ (e.g., 165℃), and the speed is 20-50 m / min (e.g., 30 m / min) to remove excess moisture from the fabric. Hot air blowing: Temperature 160-180℃; air volume 12 m³ / min. 3 / min; speed 20m / min; to make the front pile more spread out and achieve a better fluffy effect; then, the first pile layer side is subjected to front ironing and shearing at a temperature of 170~190℃ to cut off the excessively long pile, improve the flatness and hand feel of the front, and make the front pile shape basically fixed; the second pile layer side is subjected to back shearing, back shearing: shearing depth 0.5mm, lifting knife angle α=12°, circular knife speed 900r / min, to cut off the excessively long pile, so as to reduce the part of the long pile that is stretched under the action of water flow and friction of the cylinder wall after entering the cylinder; finally, the greige fabric (here referring to the greige fabric after the above-mentioned processes) is subjected to granulation and fabric rolling; granulation: the temperature inside the granulation cylinder is set at 120℃, and steam is added for granulation, making the style of the front of the fabric more refreshing and distinct, and causing the pile on the back to shrink, cohede, and even granulate again to prevent shedding; fabric rolling: the shape of the fabric after granulation is finally fixed and rolled into storage.

[0124] The working principle and beneficial effects of the above technical solution are: the processing procedure of the warp-knitted integrated pile fabric is shown in FIG. 4, which can adopt: S1. Pre-setting the back surface (i.e. pre-setting the back surface of the fabric) to make the fabric obtain a preliminary stable size and structure after the heating stage, the thermal equilibrium stage, the fiber molecular chain rearrangement stage and the cooling stage, especially to make the fabric surface tension uniform and the back surface loop size and height uniform (which is beneficial to the subsequent uniform back surface pulling or milling); S2. Milling the back surface (36-60 elastic needles or straight needles can be used to ensure that the pulled-out fine and uniform hair is not dropped and the loop root is not damaged) or milling the back surface (sandpaper milling machine is used to mill the back surface loop to break and then mill uniformly); S3. Second pre-setting of the fabric (i.e. pre-setting the front surface of the fabric) (the front surface is upward, 210-220℃, 20m / min, the temperature cannot be too high, and if it exceeds 220℃, the hand feeling of the set fabric will become hard; if it is lower than 210℃, the fabric will be soft and not hard enough, and the fabric surface will be loose due to the bending needle effect during the milling, which will cause uneven milling and the milling cannot be thorough and the lowermost extension line cannot be pulled out); S4. Milling the front surface (20-36 steel needles or bending needles can be used, the front surface hair height is relatively high, and it is not suitable to use a milling machine with a high number of rollers above 36, and the bending needle is used to hook the extension line and then break it); S5. Ironing the front surface (170-180℃, 15-20m / min, light ironing, which gives the front surface pile fabric a certain gloss and flatness); S6. Milling the back surface (the milling depth is 0.5mm, and the knife lifting angle α is used to reduce the lengthening of the back surface long hair under the action of water flow and cylinder wall friction after entering the cylinder) → S7. Dyeing (the residual floating hair after milling the back surface is washed away, which reduces the hair drop, and at the same time, the fabric is fully shrunk in the high-temperature dyeing cylinder, which makes the back surface pile more dense, and the base silk needs to be treated by alkali reduction when the base silk is island silk) → S8. Washing and softening → S9. Drying and setting (160-170℃, 30m / min can be used) → S10. Hot air blowing (160-180℃, 20m / min) to make the front surface pile more scattered and obtain better lofting effect → S11. Milling the back surface (the milling depth is 0.2mm, and the knife lifting angle β is used to mill the too long pile) → S12. Ironing and milling the front surface (to mill the too long pile, improve the flatness and hand feeling of the front surface, and make the front surface pile shape basically set) → S13. Grain shaking (120℃ steam grain shaking is used to make the back surface pile shrink, hold and even granulate again, which prevents hair drop) → S14. Fabric rolling.The processing of the back surface (S1, S2 and S6) and the front surface (S3, S4 and S5) can be independent of each other and do not interfere with each other, that is, the front surface can be processed first, or the back surface can be processed first, or the front surface and the back surface can be processed at the same time, or the different processes (S3, S4 and S5) of the front surface and the different processes (S1, S2 and S6) of the back surface can be interlaced and processed (for example, in the order of S3, S1, S4, S2, S5 and S6); that is, the processes (S3, S4 and S5) of the front surface and the processes (S1, S2 and S6) of the back surface do not form mutual restrictions, and the two surfaces of the warp-knitted integrated pile fabric can be processed independently, one surface is pulled or abraded, and the other surface is pulled, the processing of the two surfaces does not affect each other, and can be performed independently, and the above processing processes can be partially increased, reduced and adjusted in order according to the specific product style. Then, the front surface and the back surface are processed together S7, S8, S9 and S10; then, the back surface S11 and the front surface S12 are processed, the back surface S11 and the front surface S12 can be processed at the same time, or the back surface S11 can be processed first and then the front surface S12, or the front surface S12 can be processed first and then the back surface S11; finally, S13 and S14 are processed; by using the above process, the final fabric is prepared, and the finished product has a weight of 420 g / m. 2 The front surface has a pile height of 8.5 mm and presents a rabbit hair appearance effect, the back surface has fine and short pile and presents a suede appearance effect, and the front surface and the back surface not only have different pile appearance styles, but also have different colors, forming an integrated pile effect as if two fabrics are combined, the integrated pile fabric has a linting rate of 0.071% and a transverse water washing shrinkage of 0.1% through AATCC-2019 standard testing, that is, the linting rate and the transverse water washing shrinkage are low, the longitudinal tear strength is 35.7 N, and the air permeability is 1690 g / m 2 / 24hrs, that is, the longitudinal tear strength and the air permeability are good.

[0125] In the dyeing and finishing process, as shown in FIG. 6, the extended line of the front comb is broken and forms a first pile layer; the middle comb loop and the extended line do not change much and constitute part of the connecting layer; the extended line of the loose and bent back comb is converted into a loop, is elongated, is similar to a spring in a straightened state, and forms a second pile layer through pulling or abrading after being subjected to the pulling force.

[0126] In one embodiment, in the S200 step, during the knitting process, a CCD camera is used to capture images of yarn feeding and knitting machine vibration detection is performed for the yarn used for knitting;

[0127] Each single yarn is distinguished by image recognition, and according to the feeding distance of each single yarn and the detected knitting machine vibration data, simulation technology is used to simulate and analyze the vibration transmission of each single yarn to obtain the vibration data of each point in the feeding distance of each single yarn; the vibration data includes the vibration amplitude;

[0128] The machine vision recognition technology is used to pre-process the real-time images, each single yarn is distinguished by image recognition, and the vibration data of the corresponding single yarn is combined to implement image analysis of each single yarn to obtain the diameter data of each point of the real-time feeding single yarn;

[0129] The diameter data is compared with the upper and lower threshold values of the diameter of the corresponding single yarn, and if the diameter data deviates from the diameter range defined by the upper and lower threshold values, an alarm information is sent.

[0130] The working principle and beneficial effects of the above technical scheme are: the scheme considers that the yarn raw material in roll (bundle) form is not suitable for being unfolded one by one before use for diameter detection, in order to prevent the diameter deviation of the yarn in the middle of the roll (bundle) from being excessive, causing the appearance and quality of the knitted fabric to be uneven; the scheme uses machine vision recognition technology to monitor the diameter of the feeding yarn in real time, and introduces simulation technology to implement vibration transmission simulation analysis, and the vibration data obtained by analysis is considered in the diameter monitoring, thereby realizing the vibration compensation purpose of diameter monitoring, making the diameter data obtained by diameter monitoring more accurate and reliable, and reducing the diameter monitoring error; then, whether the real-time diameter data meets the requirements is judged by the allowed diameter range determined by the preset upper and lower threshold values of the diameter; for example: if the maximum size of the activity range of a point of the yarn under the influence of vibration obtained by image analysis of each single yarn is 45mm, and the vibration amplitude of the point obtained by vibration transmission simulation analysis in simulation is 21.5mm (i.e. the center of the point of the yarn will produce a radial deviation of 21.5mm in any radial direction of 360 degrees), then the real-time monitoring diameter data of the point is 2mm (i.e. 45mm-21.5mm×2=2mm); the scheme sends an alarm information when the diameter data deviates, so that the staff can take corresponding measures in time, which can improve the product quality consistency, stability and yield, reduce unqualified and defective products, and thus improve the efficiency.

[0131] In addition, a plurality of second CCD cameras can be arranged to respectively capture images of the knitting of the yarns on the respective guide bars at multiple angles, for example, from the side, top, bottom, etc. of the machine, and the images of the knitting of the yarns on the respective guide bars are pre-processed. Then, the crossing rules of the yarns on the respective guide bars, and the upper and lower level positions and structural relationships of the knitting of the yarns on the respective guide bars are determined through image recognition. For example, when the images are captured from the side of the machine, from top to bottom, the structural levels of the correct knitting can be: the front guide bar spreader yarn layer, the middle guide bar spreader yarn layer, the back guide bar spreader yarn layer, the middle guide bar loop layer, the front guide bar loop layer, and the back guide bar loop layer. The crossing rules of the yarns, and the upper and lower level positions and structural relationships of the knitting of the yarns are compared with the corresponding set standards, respectively, to determine whether they meet the requirements. For example, if the crossing rules are the same as the set crossing rule standard, it means that the requirements are met. If the requirements are not met, corresponding measures are taken to adjust. In this way, the product quality consistency, stability and yield can be further improved, the unqualified and defective products can be reduced, and the benefits can be improved.

[0132] In one embodiment, the uniformity index of the single yarn is calculated by recording the linear data of each point of the single yarn and using the following formula:

[0133] In the above formula, τ represents the uniformity index of the single yarn; n represents the total number of monitoring points of the linear data of the single yarn (i.e. also the total number of linear data); d i represents the linear data of the i-th point of the monitored single yarn; represents the mean value of the linear data of the monitored single yarn;

[0134] According to the use of each single yarn in the knitting (such as which part of the knitted fabric is used, etc.), the weight value of each single yarn is assigned;

[0135] The quality data of the knitted fabric is evaluated by combining the uniformity index of each single yarn and the weight value assigned to it. For example, the quality data of the knitted fabric can be equal to the sum of the products of the uniformity index of each single yarn and its corresponding weight value. The quality of the knitted fabric is classified and managed according to the quality data.

[0136] The working principle and beneficial effects of the above technical solution are as follows: Based on the aforementioned linear data monitoring, the uniformity of the linear data of the yarn is evaluated using a set algorithm, thereby obtaining the quality evaluation of the yarn material, which can be used as a basis for the selection of the yarn material in the future. Furthermore, the quality data of the knitted fabric is analyzed by combining the weight value of the yarn during knitting, and the quality of the knitted fabric is classified and managed accordingly. The use of this solution avoids the influence of human subjective factors in quality evaluation, and improves the objectivity and reliability of quality evaluation.

[0137] The present application can achieve the following beneficial effects:

[0138] 1. The present application uses warp-knitted structure instead of weft-knitted structure, which solves the problems of loose structure, insufficient density, easy to scatter, low connection strength between two surfaces, and the inherent structure limitation of weft-knitted fabric, and the problem of pilling caused by simple pressing of the wool yarn by the lining yarn. In addition, compared with weft-knitted fabric, warp-knitted fabric has higher production efficiency, and is easier to produce wide and ultra-wide fabric. The warp-knitted structure can be realized on a single-bed warp-knitting machine, without relying on double-bed machine or special weft-knitting equipment.

[0139] 2. The present application uses warp-knitted innovative structure, which solves the problem that the front and back of the fabric are made of the same yarn material, and the back cannot be directly used and needs to be compounded or pulled. For compounding, it increases production processes and loss, and using glue for compounding has chemical residue hazards and poor durability. For warp-knitted fabric pulling, the front part (about 40%) is pulled to the back. Essentially, the material, height and style of the back can only depend on the front, and the front and back cannot be formed and processed independently, resulting in single and similar texture, lack of creativity, and reduced fullness of the front. In the process of pulling the front to the back, the fabric structure and fibers are damaged, which further aggravates the pilling. The warp-knitted fabric of the present application does not need to be compounded or pulled through the bottom fabric, but uses the front and back as two independent systems, which effectively solves the problems of compounding and pulling the front to the back.

[0140] 3. The warp-knitted integrated pile fabric of the present application has higher degree of freedom in dyeing and finishing process, and the front and back pile can be processed independently without affecting each other. According to the final product style, the back pile can be processed first, and then the front pile, or the processing order of the front and back can be exchanged. The processing procedure of the traditional warp-knitted pile fabric is relatively fixed, and generally the front pile is processed first, and then the front pile is pulled to the back to form a double-sided pile. The processing of the weft-knitted integrated pile fabric is generally focused on the front pile, and the back part is less involved. The processing of the warp-knitted integrated pile fabric of the present application breaks the limitations of the traditional warp-knitted or weft-knitted pile fabric, and the priority and flexibility of processing the two sides are strong. The two sides can be processed by different finishing processes, and the single processing method is not limited. Moreover, the problems caused by the mutual influence and restriction of the front and back pile in the processing of the traditional double-sided pile fabric are effectively avoided. The dyeing and finishing process of the warp-knitted integrated pile fabric improves the finishing process of the weft-knitted integrated pile fabric and the conventional warp-knitted double-sided pile, making the operation more flexible. At the same time, the problems in the traditional dyeing and finishing process are avoided, and the quality of the product is improved.

[0141] 4. The warp-knitted integrated pile fabric has multiple independence in the selection of yarn materials, color selection, threading rules and appearance form of the two sides, and multiple combination between the two sides, thereby greatly improving the richness of the warp-knitted integrated pile fabric product. In addition, during the fabric processing and later use, the fabric is not prone to damage, breakage and other problems caused by loose structure and loop shedding. In addition, the transverse and longitudinal dimensional stability of the fabric is excellent, and the transverse shrinkage rate can be maintained at 0-0.2% under multiple washing conditions, which has a significant advantage over the transverse shrinkage rate of 1-3% of the traditional process product. According to the AATCC-2019 standard test, the lint shedding rate of the warp-knitted integrated pile fabric is 0.01-0.1%, less than 0.1%; the longitudinal tear strength is 25-50N; and the air permeability is 1500-2000g / m 2 / 24hrs, i.e. the air permeability is greater than 1500g / m 2 / 24hrs, thereby improving the daily use performance and comfort of the product.

[0142] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application also intends to include these modifications and variations.

Claims

1. A warp-knitted one-piece fleece fabric, characterized in that, The first plush layer and the second plush layer and the connecting layer between the first plush layer and the second plush layer; The first plush layer comprises a front comb extension thread layer formed by using the extension thread of the front comb; The connecting layer comprises a middle comb extension thread layer, a back comb extension thread layer, a middle comb loop layer and a front comb loop layer from the first plush layer to the second plush layer, and each layer is formed by using the extension thread of the middle comb, the extension thread of the back comb, the loop of the middle comb and the loop of the front comb in turn; The second plush layer comprises a back comb loop layer, a back comb extension thread layer or a combination layer of the two, wherein the back comb loop layer is formed by using the loop of the back comb, the back comb extension thread layer is formed by using the extension thread of the back comb, and the combination layer is formed by using the loop and the extension thread of the back comb.

2. The warp-knitted one-piece pile fabric according to claim 1, characterized in that The front comb adopts N+1 needle closed opening plain stitch, and the number of the padding yarn is coded as: 1-0 / N-(N+1) / / (N≥15); Or, The front comb adopts two same direction N+1 needle and P+1 needle closed opening plain stitch, and the numbers of the padding yarn are coded as: 1-0 / N-(N+1) / / (N≥15) and 1-0 / P-(P+1) / / (P≤10) respectively.

3. The warp-knitted one-piece pile fabric according to claim 1, wherein The middle comb adopts L+1 needle closed opening plain stitch, and the number of the padding yarn is coded as: L-(L+1) / 1-0 / / (1≤L≤3); Or, The middle comb adopts two opposite direction L+1 needle closed opening plain stitch, and the numbers of the padding yarn are coded as: L-(L+1) / 1-0 / / (1≤L≤3) and 1-0 / L-(L+1) / / (1≤L≤3) respectively.

4. The warp-knitted one-piece pile fabric according to claim 1, wherein The back comb adopts M+1 needle opening plain stitch, and the number of the padding yarn is coded as: 0-1 / (M+1)-M / / (2≤M≤5); Or, The back comb adopts M needle weft insertion stitch, and the number of the padding yarn is coded as: M-M / 0-0 / / (2≤M≤5); Or, The back comb adopts M+1 needle opening plain stitch, and the number of the padding yarn is coded as: (M+1)-M / 0-1 / / (2≤M≤5); Or, The back comb adopts two opposite direction M+1 needle opening plain stitch, and the numbers of the padding yarn are coded as: 0-1 / (M+1)-M / / (2≤M≤5) and (M+1)-M / 0-1 / / (2≤M≤5) respectively, or the back comb adopts two opposite direction M needle weft insertion stitch, and the numbers of the padding yarn are coded as: 0-0 / M-M / / (2≤M≤5) and M-M / 0-0 / / (2≤M≤5) respectively, or the back comb adopts one M+1 needle opening plain stitch and one M needle weft insertion stitch, and the numbers of the padding yarn are coded as: 0-1 / (M+1)-M / / and 0-0 / M-M / / (2≤M≤5) respectively.

5. The warp-knitted one-piece pile fabric according to claim 1, wherein The front comb selects 75-300D polyester DTY round hole low elastic filament, and the single filament fineness range is 0.52-1.04D, or 75-300D polyester FDY flat section filament, and the single filament fineness range is 1.04-4.16D; The middle comb selects 50-100D polyester FDY or DTY ordinary polyester filament; The back comb selects 75-300D polyester DTY round hole low elastic filament, and the single filament fineness range is 0.52-1.04D; or selects one of 75-300D polyester sea island filament, original liquid colored polyester filament, lyocell filament and mulberry silk.

6. The method of manufacturing a warp-knitted one-piece pile fabric according to any one of claims 1 to 5, characterized in that, The method comprises the following steps: S100: determine the knitting yarn raw material, and use the selected warper to warp the yarn; S200: use the warp knitting machine configured with not less than three guide bars to divide the guide bars into three groups for front guide, middle guide and back guide knitting, and perform on-machine knitting; A. threading: front guide: 1 threading 1 empty; middle guide: full threading; back guide: full threading; B. knitting: perform the knitting process according to the following let-off amount: front guide: the actual let-off amount used is 0.9-1.1 times the calculated let-off amount; middle guide: the actual let-off amount used is 0.85-0.95 times the calculated let-off amount; back guide: the actual let-off amount used is 1.5-3 times the calculated let-off amount; the pulling density used in knitting is 13-20 cpc, and the starting speed is 1500-2200 rpm; S300: perform dyeing and finishing processing on the knitted fabric to obtain the warp-knitted integrated pile fabric.

7. The method of claim 6, wherein the warp-knitted one-piece pile fabric is prepared by using a pile yarn having a length of 20 to 30 mm and a weight of 1.5 to 2.5 g / m. In the step S200, before on-machine knitting, the back guide tension compensation device is adjusted, that is, the tension rod of the back guide tension compensation device is extended forward by 15-35 cm; and the back guide tension compensation device uses a tension spring with a tension sensitivity of not less than 0.1 cN.

8. The method of claim 6, wherein the warp-knitted one-piece pile fabric is prepared by using a pile yarn having a length of 20-30 mm and a weight of 20-30 g / 1000 m. In the step S100, the yarn warping method is as follows: front guide: use SGZ400D intelligent computer-controlled warper, disc head specification: Φ21x21”; warping head number: 293; warping disc head number: 8; warping speed: 1200 rpm; warping tension: 8-9 cN; middle guide: use SGZ300D computer-controlled high-speed warper, disc head specification: Φ21x21”; warping head number: 588; warping disc head number: 8; warping speed: 1500 rpm; warping tension: 5-6 cN; back guide: use SGZ400D intelligent computer-controlled warper, disc head specification: Φ21x21”; warping head number: 588; warping disc head number: 8; warping speed: 1200 rpm; warping tension: 8-9 cN.

9. The method of claim 6, wherein the warp-knitted one-piece pile fabric is prepared by using a pile yarn having a length of 20-30 mm and a weight of 20-30 g / 1000 m. In the step S300, the dyeing and finishing processing comprises: performing fabric back pre-setting, back fluffing or milling, and back shearing on the second pile layer side in sequence; performing fabric front pre-setting, front fluffing, and front glazing on the first pile layer side in sequence; performing dyeing, softening, drying, and hot blowing on the first pile layer side and the second pile layer side after the front processing; then performing front shearing on the first pile layer side and back shearing on the second pile layer side; finally, performing grain processing and fabric rolling on the fabric.

10. The method of claim 6, wherein the warp-knitted one-piece pile fabric is prepared by using a pile yarn having a length of 20-30 mm and a weight of 20-30 g / 1000 m. In the knitting process, for the knitting yarn, a CCD camera is used to take images of the yarn feeding, and the knitting machine vibration is detected; each single yarn is distinguished through image recognition, and according to the feeding distance of each single yarn and the detected knitting machine vibration data, simulation technology is used to simulate and analyze the vibration transmission of the single yarn, to obtain the vibration data of each point in the feeding distance of each single yarn; the vibration data includes vibration amplitude; Adopt machine vision identification technology, to the real-time image shooting image pre-processing, through image recognition to each single yarn is distinguished, combined with the corresponding single yarn vibration data, implementation of each single yarn image analysis, get real-time feeding single yarn each point of the line diameter data; The line diameter data and the corresponding single yarn line diameter upper threshold and line diameter lower threshold are compared, if the line diameter data deviates from the line diameter range defined by the line diameter upper threshold and the line diameter lower threshold, the warning information is sent out.

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