Warp-Knitted Multi-Layer Jacquard Shoe Upper for Strength and Breathability
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Solution Overview
Problem
Existing warp-knitted jacquard shoe upper fabrics face limitations in jacquard variation layers, fabric strength, and the ability to achieve lightweight and breathable effects, with traditional weaving technologies resulting in overlapping patterns and structural layers that restrict design complexity and quality.
Innovation Solution
A preparation process utilizing a combination of ground, pattern, and jacquard guide bars, including loop-forming and weft-insertion jacquards, to create a multi-layer jacquard structure with increased jacquard variation, improved fabric strength, and a lightweight, breathable effect, using specific yarns and lapping structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional warp beam yarn supply systems with spacer layers or double jacquard devices are used, then basic jacquard structure is achieved, but pattern layers and color performance are restricted
Solution Approach 1:
The patent divides the jacquard structure into multiple independent layers (first jacquard layer, second jacquard layer, third jacquard layer) with distinct functions. Each layer uses separate yarn supply systems and guide bars, allowing independent pattern design and color selection. This segmentation enables complex multi-layer patterns while maintaining manageable structural complexity through modular organization.
Solution Approach 2:
The patent transitions from traditional single-layer or two-layer jacquard to a three-layer vertical structure. By adding the third jacquard layer with its own yarn supply system, the design space expands from 2D planar patterns to 3D multi-level patterns, enabling richer color performance and pattern complexity without proportionally increasing device complexity.
2Adaptability or versatility
If warp-knitted multi-guide bar jacquard single-needle bed fabrics with large-range lapping are used, then rich patterns are formed, but the structure lacks fishing line reinforcement resulting in poor strength
Solution Approach 1:
The patent creates a composite structure by integrating transparent fishing line (TPEE yarn) with traditional jacquard yarns. The fishing line forms a reinforcement layer that penetrates through the jacquard structure, combining the pattern-forming capability of jacquard yarns with the high strength of fishing line. This composite approach maintains rich pattern diversity while significantly improving fabric strength and durability.
Solution Approach 2:
The transparent fishing line acts as an intermediary reinforcement element that connects and stabilizes the multiple jacquard layers. It serves as a structural mediator that distributes mechanical stresses across the fabric without interfering with the pattern formation processes of the jacquard guide bars, thus preserving pattern richness while enhancing overall fabric strength.
3Quantity of substance
If thicker jacquard raw materials (75D-300D) are used, then material availability increases, but weaving stability becomes unstable and quality deteriorates
Solution Approach 1:
The patent applies different yarn specifications to different functional layers: thinner yarns (75D-150D) for the first and second jacquard layers requiring high weaving stability, and thicker fishing line (300D-500D) for the reinforcement layer requiring high strength. This localized quality assignment optimizes both weaving stability for pattern layers and structural strength for the reinforcement layer, resolving the contradiction between material availability and weaving reliability.
4Ease of manufacture
If ground guide bars and jacquard guide bars are used for weaving, then basic jacquard structure is formed, but overlapping patterns and structural layers limit the layering effect
Solution Approach 1:
The patent segments the guide bar system into three distinct types: ground guide bars for basic structure, pattern guide bars for intermediate layers, and jacquard guide bars for surface patterns. Each guide bar type controls a specific layer independently, preventing pattern overlap and enabling clear multi-layer differentiation. This segmentation maintains relatively simple weaving processes while dramatically improving the layering effect and design versatility.
Data Source
AI summary
The present application relates to the technical field of textiles and provides a preparation process for a warp-knitted jacquard multi-layer jacquard shoe upper fabric, aiming to solve the problems of insufficiently rich jacquard variation layers, relatively poor fabric strength, and the inability to simultaneously achieve lightweight and breathable effects in existing warp-knitted double jacquard single-layer fabrics. The process includes: (1) Guide Bar Setup: The guide bars of the weaving machine include ground guide bars, pattern guide bars, and jacquard guide bars. (2) Guide Bar Threading and Weaving: The ground guide bars GB1 and GB2 are fully threaded. The pattern guide bars PB3-PB74 are threaded according to the designed pattern effects to form arbitrary weft-inserted jacquard structures. The ground guide bar GB1 wraps all other layers of yarns through loops and underlaps. The ground guide bar GB2 locks all layers of yarns except GB1.