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CN-122013419-A - Knitting fabric weaving method with gradient density structure

CN122013419ACN 122013419 ACN122013419 ACN 122013419ACN-122013419-A

Abstract

The invention discloses a knitting fabric weaving method with a gradient density structure, which relates to the technical field of weaving and comprises the steps of cooperatively designing raw material components and a multi-layer tissue structure, and constructing a physical model of a density gradient in the thickness direction; configuring technological parameters of equipment, establishing a mapping relation, controlling the raw materials of all layers to perform integrated weaving and forming to form a multi-layer structure with a continuous interface, monitoring tension fluctuation in real time by using a sensor, adjusting yarn feeding quantity in a closed loop, and finally performing heat setting treatment. The capillary pressure difference is generated by combining asymmetric pore distribution formed by the combination of the fine denier fiber of the surface layer, the high-elastic monofilament of the middle layer and the coarse denier yarn of the inner layer and the composite tissue. The invention realizes efficient unidirectional moisture conduction and thermal moisture management performance, enhances structural stability and durability, has environment-friendly process and remarkably improves production efficiency and product consistency.

Inventors

  • LI JIANWEN

Assignees

  • 佛山市昶瑞纺织有限公司

Dates

Publication Date
20260512
Application Date
20260401

Claims (10)

  1. 1. The knitting cloth weaving method with the gradient density structure is characterized by comprising the following steps: Step 1, cooperatively designing a raw material combination and a multi-layer tissue structure, respectively selecting components of a surface layer raw material, a middle layer raw material and a lining raw material according to preset moisture absorption and sweat release performance indexes, designing a composite knitting structure comprising a plating structure and a weft insertion structure, and constructing a preliminary physical model with a thickness direction density gradient through the pre-configuration of the surface layer raw material, the middle layer raw material and the lining raw material on a geometric topological structure; Step 2, configuring technological parameters of weaving equipment, setting yarn feeding speed of a yarn feeding device, dynamic tension of a weaving mechanism and coil length of a looping system in a segmented mode based on the preliminary physical model, and converting structural requirements into machine execution instructions by establishing a mapping relation between raw material characteristics and technological parameters of the raw material combination; Step 3, performing integrated weaving forming, starting knitting equipment, controlling the surface layer raw material, the middle layer raw material and the inner layer raw material to synchronously weave according to a preset tissue cycle, and finishing interweaving in the same looping cycle by utilizing a multi-path yarn feeding system to directly form a multi-layer integrated fabric structure with continuous interfaces in a weaving link; step 4, dynamically monitoring and closed-loop adjustment, wherein an online monitoring sensor is utilized to collect yarn tension fluctuation data in the weaving process in real time, the collected tension signal is transmitted to a central processing unit, and the yarn feeding quantity is corrected in real time through a feedback control loop so as to compensate the influence caused by raw material difference and maintain the uniformity of a gradient density structure; and 5, carrying out post-treatment and finished product detection, carrying out heat setting treatment on the knitted fabric after weaving, inducing the fibers to physically shrink through heat energy so as to solidify the gradient density structure, detecting the porosity distribution and the unidirectional moisture permeability index of the gradient density structure in the thickness direction, and verifying the directional conduction efficiency of liquid moisture of the gradient density structure.
  2. 2. The method for weaving the knitted fabric with the gradient density structure according to claim 1, wherein in the step 1, fine denier chemical fiber filaments are selected as the surface layer raw material, the chemical fiber filaments comprise polyester fibers or polyamide fibers, a high-density surface layer structure is formed by closely arranging high-count filaments, the surface layer raw material is subjected to cold plasma treatment before weaving so as to increase the roughness and hydrophilic group content of the surface of the fibers, the cross section of the surface layer raw material is a special-shaped cross section, capillary force is generated by micro grooves formed by the special-shaped cross section, coarse denier yarns or blended yarns are selected as the inner layer raw material, the blended yarns are formed by blending combed cotton fibers and modified polyester fibers in a preset proportion, silver ion modified fibers are distributed in the inner layer raw material, liquid sweat is contained in a coil cavity volume formed by the coarse denier yarns, and a high-elasticity monofilament is selected as the connecting tie of the surface layer raw material and the inner layer raw material.
  3. 3. The method for weaving the knitted fabric with the gradient density structure according to claim 1 is characterized in that in the step 1, the composite knitted fabric is woven by a double-sided circular knitting machine, the surface layer raw material is a flat knitting plating fabric, the inner layer raw material is a combined structure of tuck stitch and weft insertion fabric, asymmetric pore distribution is formed in the fabric by changing the distribution density of tuck spots, a capillary pressure difference from inside to outside is generated, tuck suspension tissue is also introduced into the composite knitted fabric, a loop forming spot is reduced in a specific area, an air layer with heat insulation performance and moisture migration buffering effect is formed, when the preliminary physical model is constructed, parameter configuration of each layer is determined by calculating a capillary pressure gradient in the thickness direction, a preset small equivalent capillary pore diameter is configured at the surface layer raw material, a preset large equivalent capillary pore diameter is configured at the inner layer raw material, and pressure difference driving in the thickness direction is realized.
  4. 4. The method according to claim 1, wherein in the step 2, the yarn feeding speed of the inner layer material is set to a first preset yarn feeding speed, the yarn feeding speed of the middle layer material is set to a second preset yarn feeding speed, the yarn feeding speed of the surface layer material is set to a third preset yarn feeding speed, the stitch size is controlled by the differentiated yarn feeding speed, the stitch formed by the inner layer material is ensured to have a relaxation space for forming air holes, the stitch formed by the surface layer material is in a limited state for forming compact small air holes, the control of the knitting tension is realized by an electronic weft accumulator, the dynamic tensions of the inner layer material, the middle layer material and the surface layer material are respectively set to a first preset tension value, a second preset tension value and a third preset tension value, the stitch length of the looping system is realized by adjusting the needle pressing depth, and the stitch lengths of the inner layer material and the surface layer material are respectively set to a first preset length and a second preset length.
  5. 5. The method for weaving the knitted fabric with the gradient density structure according to claim 1, wherein in the step 2, the mapping relation between the raw material characteristics and the process parameters is realized by establishing a mathematical model, the mathematical model comprehensively considers the friction coefficient, the elastic modulus and the bending stiffness of yarns, predicts the density distribution of the fabric under different parameter combinations through numerical simulation, controls the prediction error within a preset error range, and is also used for optimizing the elastic modulus selection of the middle layer raw material according to specific functional requirements, so that the stability of the gradient of the porosity is maintained through the supporting and limiting effects of the middle layer raw material when the fabric is subjected to multi-directional stretching, the collapse of the interlayer structure is prevented, and the smoothness of a water conduction channel is ensured.
  6. 6. The method for weaving the knitted fabric with the gradient density structure according to claim 1, wherein in the step 3, needle bed needle pitches of the knitting equipment are set to be preset needle pitches, a multi-path yarn feeding mode is adopted, each path of yarn feeding system is provided with an independent tension compensation device, the fact that the surface layer raw material, the middle layer raw material and the inner layer raw material are interwoven in the same looping cycle is guaranteed, in the looping process of each path, the surface layer raw material firstly enters a looping track, then the middle layer raw material and the inner layer raw material are sequentially fed, a multi-layer integrated fabric structure with a continuous interface is formed through cooperation of time difference and space displacement, a full-automatic doffing device is adopted in the weaving process, the diameter of a fabric roll is monitored through an infrared sensor, the cutting and the changing of the roll are automatically performed when the diameter reaches a preset diameter threshold value, and the knitting equipment is further provided with an automatic end-breaking automatic stop device, and an alarm signal is sent when any path of raw material breaks or is abnormal in tension.
  7. 7. The method for weaving the knitted fabric with the gradient density structure according to claim 1, wherein in the step 4, the on-line monitoring sensor is a piezoelectric tension sensor, the piezoelectric tension sensor is deployed between a yarn feeding port and a looping area, the sensor transmits an acquired tension signal to the central processing unit through an analog-to-digital conversion circuit, the central processing unit eliminates high-frequency noise in the signal by utilizing a digital filtering algorithm and calculates a correction value of a yarn feeding amount by adopting a proportional integral differential control algorithm, the correction value is determined together according to a real-time tension deviation, a proportional coefficient, an integral coefficient and a differential coefficient, the central processing unit drives a servo motor to adjust the rotating speed of a yarn feeding disc, the adjusting precision reaches a preset precision value, thereby compensating coil size deviation caused by raw material difference or tension fluctuation and maintaining uniformity of the gradient density structure in a whole roll of fabric.
  8. 8. The method for weaving the knitted fabric with the gradient density structure according to claim 1, wherein in the step 5, the heat setting treatment is performed on a tentering setting machine, setting temperature is within a preset temperature range, treatment time is within a preset time period, chemical fibers are subjected to physical shrinkage through heat energy to solidify the gradient density structure, size stability of the fabric is improved, in the heat setting treatment process, the width and overfeed rate of the fabric are monitored in real time, the formed pore gradient is prevented from being damaged by overstretched, the heat setting treatment also adopts a sectional temperature control mode, different temperature gradients are set in different sections of the tentering setting machine so as to adapt to heat shrinkage differences of different fiber contents in a functional area, and fabric surface flatness and structural consistency of a finished fabric are ensured.
  9. 9. The method according to claim 1, wherein the detecting process comprises evaluating a wet-out time, a water absorption rate, a maximum wet-out radius, a diffusion speed and a unidirectional moisture permeability index by using a liquid moisture management tester, wherein the unidirectional moisture permeability index is required to meet a preset moisture permeability threshold, the porosity distribution of the gradient density structure in the thickness direction shows a nonlinear variation, the porosities of the inner layer raw material, the middle layer raw material and the surface layer raw material are respectively set in a first preset porosity range, a second preset porosity range and a third preset porosity range, a pressure driving force is generated by arranging from loose to dense structures, and the detecting process further comprises evaluating the surface friction characteristics of the fabric, wherein the surface friction coefficient is controlled in a preset low numerical range by controlling the arrangement density of the surface layer raw material, so that the abrasion resistance of the fabric is improved.
  10. 10. The method for weaving the knitted fabric with the gradient density structure according to claim 1, further comprising the steps of controlling the temperature and humidity of a weaving environment, keeping the temperature of a workshop within a preset environment temperature range, keeping the relative humidity within a preset environment humidity range, arranging an active ion neutralization device and a conductive ceramic yarn passing piece on a yarn feeding path to inhibit the influence of static electricity on the weaving process of the fine denier filaments, forming a high-air-permeability area and a high-support area with different porosities on the surface of the fabric by adjusting the arrangement frequency of weft-inserted yarns of weft-inserted tissues, wherein the porosity of the high-air-permeability area is improved by a preset proportion compared with that of a conventional area, controlling the total gram weight of the knitted fabric produced by the method within a preset gram weight range, controlling the thickness within a preset thickness range, and controlling the longitudinal shrinkage and the transverse shrinkage to be smaller than or equal to preset shrinkage threshold.

Description

Knitting fabric weaving method with gradient density structure Technical Field The invention belongs to the technical field of textile, and particularly relates to a knitting fabric weaving method with a gradient density structure. Background With the deep fusion of textile industry and material science, functional knitted fabrics are increasingly widely applied in the fields of outdoor sports, health care and special protection. As a core index for improving the wearing comfort of the garment, the heat and moisture transfer performance of the fabric directly influences the balance of human microenvironment. In order to realize efficient sweat management, researchers endow the fabric with the functions of moisture absorption and sweat release, unidirectional moisture conduction and dynamic heat regulation by changing the fiber arrangement and the fabric geometry, which has become an important direction of innovation of modern textile technology. The knitted fabric with the gradient density structure utilizes the differential distribution of the physical structure to construct the capillary pressure gradient from inside to outside, and is a key path for realizing the unidirectional moisture guiding function. Such fabrics typically involve a composite design of a multi-layer tissue that promotes rapid migration and diffusion of moisture from the skin-contacting surface to the outer layer by precisely controlling the porosity, fiber density, and wettability differences of the inner and outer layers. Under high-strength sports and complex environments, the gradient density structure not only can keep skin dry and comfortable, but also can maintain long-acting functional performance through the stability of the structure. However, in the prior art, when a gradient density structure is constructed, a multi-layer fabric compounding or chemical after-finishing means are mostly adopted, so that the interlayer binding force is insufficient, the peeling risk is easy to occur, and the washing fastness and the service life of the fabric are seriously affected. Meanwhile, when the traditional weaving process is used for processing heterogeneous fiber combination, dynamic cooperative control on yarn feeding amount and weaving tension is often lacked, and porosity gradual change in the thickness direction is difficult to accurately define in a single forming process. In addition, because the fiber composition is relatively single and the tissue structure lacks layering nesting, the existing fabric has natural contradiction in terms of high strength quick drying and soft moisture absorption, and can not meet the severe requirements of high-quality functional fabric on structural continuity and performance compounding. Disclosure of Invention The invention aims to provide a knitting fabric weaving method with a gradient density structure, which can effectively solve the problems in the background technology. In order to achieve the above purpose, the technical scheme adopted by the invention is as follows: A knitting fabric weaving method with a gradient density structure comprises the following specific steps of 1, cooperatively designing a raw material combination and a multi-layer structure, respectively selecting raw material components of a surface layer, a middle layer and an inner layer according to preset moisture absorption and sweat releasing performance indexes, designing a composite knitting structure comprising a plating structure and a weft insertion structure to construct a preliminary physical model with a density gradient in the thickness direction, 2, configuring weaving equipment process parameters, setting yarn feeding speed of a yarn feeding device, dynamic tension of a weaving mechanism and coil length of a looping system in a segmented mode based on the physical model designed in the step 1, establishing a mapping relation between raw material characteristics and the process parameters, 3, executing integrated weaving forming, starting knitting equipment, controlling the raw material of the surface layer, the raw material of the middle layer and the raw material of the inner layer to be woven synchronously according to preset tissue circulation, directly forming the multi-layer integrated fabric structure with continuous interfaces in a weaving link, 4, dynamically monitoring and adjusting in a closed loop mode, acquiring yarn tension fluctuation data in a weaving process in real time by utilizing an on-line monitoring sensor, correcting yarn feeding quantity in real time through a feedback control loop, guaranteeing uniformity of the gradient density structure, 5, carrying out post-treatment and finished product detection, carrying out finishing treatment on the weaving and detecting the finished fabric, carrying out thermal conductivity and checking the gradient density distribution in the direction, and checking the moisture permeability index. Preferably, in the step 1, the surface layer raw materi