FLAT-KNITTED THREE-DIMENSIONAL FABRIC WITH INTERNAL SUPPORT STRUCTURE, AND METHOD FOR PREPARING SAME

Abstract

A flat-knitted three-dimensional fabric with an internal support structure, and the fabric is consisted of an upper surface layer, a lower surface layer, and a support structure yarn in a middle, wherein the upper surface layer and the lower surface layer comprise alternate-knitted single-sided stitches and fully-knitted single-sided stitches; the upper surface layer and the lower surface layer are connected by means of tuck knitting of the support structure yarn in the middle to form the integrally formed three-dimensional fabric with an internal support structure; and the alternate-knitted single-sided stitches are correspond to tuck loops formed by the support structure yarn and are used to lock the tuck loops formed by the support structure yarn in the middle, such that the support structure yarn will not puncture the surfaces of the fabric when the fabric is pressed.

Claims

1. A flat-knitted three-dimensional fabric with an internal support structure, being consisted of an upper surface layer, a lower surface layer, and a support structure yarn in a middle, wherein the upper surface layer and the lower surface layer comprise alternate-knitted single-sided stitches and fully-knitted single-sided stitches; the upper surface layer and the lower surface layer are connected by means of tuck knitting of the support structure yarn in the middle to form the integrally formed three-dimensional fabric with an internal support structure; and the alternate-knitted single-sided stitches are connected to tuck loops formed by the support structure yarn and are used to lock the tuck loops formed by the support structure yarn in the middle.

2. The flat-knitted three-dimensional fabric with an internal support structure according to claim 1, wherein the upper surface layer and the lower surface layer of the fabric further comprise meshes, and the meshes on the upper surface layer and the meshes on the lower surface layer are formed by a loop-transfer knitting process.

3. The flat-knitted three-dimensional fabric with an internal support structure according to claim 1, wherein the support structure yarn in the middle of the fabric is a 50 D-1000 D polyester monofilament.

4. The flat-knitted three-dimensional fabric with an internal support structure according to claim 1, wherein a thickness of the flat-knitted three-dimensional fabric with an internal support structure is 5 mm-28 mm.

5. A method for preparing the flat-knitted three-dimensional fabric with an internal support structure according to claim 1, wherein the fabric is knitted on a four-needle bed computerized flat knitting machine, and the upper surface layer and the lower surface layer of the fabric are two single-sided stitch fabrics knitted by the computerized flat knitting machine.

6. The method according to claim 5, comprising: knitting two courses of fully-knitted single-sided stitches of the upper surface layer and the lower surface layer from a yarn on the four-needle bed computerized flat knitting machine provided with an electronic needle selection device by means of a tubular knitting process, then knitting tuck loops on two needle beds, used for knitting the upper surface layer and the lower surface layer, from a support structure yarn to connect the upper surface layer and the lower surface layer into a whole, then knitting two wales of fully-knitted single-sided stitches of the upper surface layer and the lower surface layer on the computerized flat knitting machine by means of the tubular knitting process, and then knitting two courses of single-sided stitches every one stitch from the yarn of the upper surface layer and the lower surface layer on the computerized flat knitting machine by means of the tubular knitting process, wherein after the support structure yarn is tuck-knotted, the one-sided stitches are knotted every one stitch to lock tuck loop structures, such that the support structure yarn is prevented from punching surfaces of the fabric when the fabric is pressed.

7. The method according to claim 5, wherein the support structure yarn in the middle is tuck-knitted on the computerized flat knitting machine as follows: multiple layers of tuck loops with a same connecting distance are alternate-knitted between a front lower needle bed and a back lower needle bed.

8. The method according to claim 5, wherein the computerized flat knitting machine is a four-needle bed computerized flat knitting machine and is provided with a front lower needle bed, a back lower needle bed, a front upper needle bed and a back upper needle bed, wherein the front lower needle bed and the back lower needle bed are able to perform both knitting and loop transfer, and the front upper needle bed and the back upper needle bed are able to perform both knitting and loop transfer or are able to perform loop-transfer only.

9. The method according to claim 5, wherein the upper surface layer and the lower surface layer of the fabric further comprises meshes, and the meshes are formed by loop transfer by 1-8 stitches of a loop-transfer process of the computerized flat knitting machine when the fully-knitted single-sided stitches of the upper surface layer and the lower surface layer are knitted, such that size-variable mesh structures are formed under the condition that a large surface density of the fabric is guaranteed.

10. A seat cover comprising the flat-knitted three-dimensional fabric with an internal support structure according to claim 1.

11. A shoe comprising the flat-knitted three-dimensional fabric with an internal support structure according to claim 1.

12. A bag comprising the flat-knitted three-dimensional fabric with an internal support structure according to claim 1.

13. A mattress comprising the flat-knitted three-dimensional fabric with an internal support structure according to claim 1.

14. The flat-knitted three-dimensional fabric with an internal support structure according to claim 2, wherein the support structure yarn in the middle of the fabric is a 50 D-1000 D polyester monofilament.

15. The method according to claim 6, wherein the support structure yarn in the middle is tuck-knitted on the computerized flat knitting machine as follows: multiple layers of tuck loops with a same connecting distance are alternate-knitted between a front lower needle bed and a back lower needle bed.

16. The method according to claim 8, wherein the upper surface layer and the lower surface layer of the fabric further comprises meshes, and the meshes are formed by loop transfer by 1-8 stitches of a loop-transfer process of the computerized flat knitting machine when the fully-knitted single-sided stitches of the upper surface layer and the lower surface layer are knitted, such that size-variable mesh structures are formed under the condition that a large surface density of the fabric is guaranteed.

17. The method according to claim 5, wherein the single-sided stitches of the upper surface layer and the lower surface layer of the fabric are weft plain stitches knitted from the yarn, and the yarn of the upper surface layer and the lower surface layer is a same yarn and is fed by a common yarn guide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a structural diagram of a flat-knitted three-dimensional fabric with an internal support structure and surfaces with meshes according to the invention, wherein 1, upper surface layer; 2, lower surface layer; 3, mesh on the upper surface layer; 4, mesh on the lower surface layer; 5, support structure yarn.

[0024] FIG. 2 is a knitting principle diagram of the flat-knitted three-dimensional with an internal support structure and surfaces with meshes according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0025] The preferred embodiments of the invention will be described below. It should be understood that the following embodiments are merely used to better explain the invention, and are not intended to limit the invention.

[0026] Embodiment 1: Flat-Knitted Three-Dimensional Fabric with an Internal Support Structure

[0027] As shown in FIG. 1, a flat-knitted three-dimensional fabric with an internal support structure comprises a fabric body, wherein the fabric body is consisted of an upper surface layer 1, a lower surface layer 2, and a support structure yarn 5 in the middle. The upper surface layer 1 and the lower surface layer 2 are two single-sided stitch fabrics knitted by a computerized flat knitting machine. Wherein, single-sided stitches of the upper surface layer 1 and the lower surface layer 2 comprise alternate-knitted single-sided stitches, fully-knitted single-sided stitches and meshes. The meshes 3 on the upper surface layer and the meshes 4 on the lower surface layer are formed by a loop-transfer knitting process of the computerized flat knitting machine. The upper surface layer 1 and the lower surface layer 2 are connected by means of the support structure yarn 5 in the middle by tuck stitch to form the integrally formed three-dimensional fabric with an internal support structure. Wherein, the upper surface layer 1 and the lower surface layer 2 of the fabric may be knitted from the same yarn fed by the same yarn guide, such that side edges of the fabric of the invention are automatically sewn together.

[0028] The single-sided stitches of the upper surface layer 1 and the lower surface layer 2 of the fabric comprises the alternate-knitted single-sided stitches used for locking tuck loops formed by the support structure yarn in the middle, such that the support structure yarn will not puncture the surfaces of the fabric when the fabric is pressed.

[0029] The single-sided stitches of the upper surface layer 1 and the lower surface layer 2 comprise the fully-knitted single-sided stitches that are knitted on the upper surface layer 1 and the lower surface layer by means of loop transfer by 1-8 stitches of the loop transfer process of the computerized flat knitting machine, such that size-variable mesh structures are formed under the condition that a large surface density of the fabric is guaranteed.

[0030] The single-sided stitches of the upper surface layer 1 and the lower surface layer 2 of the fabric are weft plain stitches knitted from a yarn, and the upper surface layer 1 and the lower surface layer 2 may be knitted from the same yarn fed by a common yarn guide.

[0031] The support structure yarn 5 in the middle is tuck-knitted on the computerized flat knitting machine to form multiple layers of tuck loops with the same connecting distance. Wherein, the connecting distance may be adjusted according to the thickness of the desired three-dimensional fabric with an internal support structure; the thickness of the fabric may be controlled to 5 mm-28 mm by changing the diameter of the yarn and the distance between the tuck loops of the support structure yarn; the surface density of the fabric is 0.04 g/cm.sup.2-0.36 g/cm.sup.2; and the breathability of the fabric is 160-880 mm/s.

[0032] Embodiment 2: Method for Preparing a Flat-Knitted Three-Dimensional Fabric with an Internal Support Structure

[0033] This embodiment provides a method for preparing a flat-knitted three-dimensional fabric with an internal support structure, wherein the fabric comprises a fabric body consisted of an upper surface layer 1, a lower surface layer 2, and a support structure yarn 5 in the middle. The upper surface layer 1 and the lower surface layer 2 are two single-sided stitch fabrics knitted by a computerized flat knitting machine. Wherein, single-sided stitches of the upper surface layer 1 and the lower surface layer 2 comprise alternate-knitted single-sided stitches, fully-knitted single-sided stitches and meshes. The meshes 3 on the upper surface layer and the meshes 4 on the lower surface layer are formed by a loop-transfer knitting process of the computerized flat knitting machine. The upper surface layer 1 and the lower surface layer 2 are connected by tuck stitch by means of the support structure yarn 5 in the middle to form the integrally formed three-dimensional fabric with the internal support structure. The method comprises the following steps:

[0034] Two courses of fully-knitted single-sided stitches of the upper surface layer 1 and the lower surface layer 2 are knitted from the same yarn on a four-needle bed computerized flat knitting machine provided with an electronic needle selection device by means of a tubular knitting process; then, tuck loops are knitted from the support structure yarn 5 on two needle beds for knitting the upper surface layer 1 and the lower surface layer 2 to connect the upper surface layer 1 and the lower surface layer 2 into a whole; next, two wales of fully-knitted single-sided stitches of the upper surface layer 1 and the lower surface layer 2 are knitted on the computerized flat knitting machine by means of the tubular knitting process; then, two courses of single-sided stitches are knitted every one stitch from the yarn of the upper surface layer 1 and the lower surface layer 2 on the computerized flat knitting machine by means of the tubular knitting process, wherein after the tuck loops are knitted from the support structure yarn 5, the single-sided stitches are knitted every one stitch to lock the tuck loops, such that the support structure yarn will not puncture the surfaces of the fabric when the fabric is pressed.

[0035] According to the method, when the fully-knitted single-sided stitches of the upper surface layer 1 and the lower surface layer 2 are knitted, loop transfer by 1-8 stitches may be performed by the four-needle bed computerized flat knitting machine to form the meshes 3 on the upper surface layer and the meshes 4 on the lower surface layer, wherein a front upper needle bed and a back upper needle bed of the four-needle bed computerized flat knitting machine are used to assist in loop transfer on a back lower needle bed and a front lower needle bed, so idle needles for reversing do not need to be reserved on the front lower needle bed and the back lower needle bed, and the upper surface layer 1 and the lower surface layer 2 of the three-dimensional fabric with an internal structure are fully knitted, thus improving the surface density of the surfaces of the fabric.

[0036] The front upper needle bed and the back upper needle bed of the four-needle bed computerized flat knitting machine are able to perform both knitting and loop transfer or are able to perform loop transfer only.

[0037] To knit the flat-knitted three-dimensional fabric with an internal support structure and surfaces with meshes in Embodiment 1, this embodiment specifically adopts the following knitting method:

[0038] As shown in FIG. 2, knitting is performed on a four-needle bed computerized flat knitting machine, and two yarn guides A and B are used, wherein A represents a yarn guide for 900 D polyamide yarns, B represents a yarn guide for 400 D polyester monofilaments; FD represents a front lower needle bed, and BD represents a back lower needle bed.

[0039] .fwdarw. and ← represent movement directions of the yarn guides and respectively indicate that the yarn guides move front left to right and from right to left.

[0040] ⋅ represents needles on the needle bed.

[0041] represents loops knitted on the front lower needle bed.

[0042] represents loops knitted on the back lower needle bed.

[0043] represents tuck loops knitted on the front lower needle bed.

[0044] represents tuck loops knitted on the back lower needle bed.

[0045] represents leftward transfer by one stitch of loops on the front lower needle bed.

[0046] represents leftward transfer by one stitch of loops on the back lower needle bed.

[0047] The knitting process is as follows:

[0048] A first course and a second course are knitted on the front lower needle bed FD and the back lower needle bed BD respectively by means of the yarn guide A, that is, the upper surface layer and the lower surface layer of the fabric are formed respectively.

[0049] A third course to a sixth course are tuck-knitted every four stitches from the support structure yarn by means of the yarn guide B to connect the upper surface layer in the first course and the lower surface layer in the second course, wherein tuck loops knitted on the same needle bed are arranged at intervals.

[0050] A seventh course and an eighth course are knitted on the front lower needle bed FD and the back lower needle bed BD respectively by means of the yarn guide A.

[0051] Weft plain stitches of a ninth course are knitted every one stitch on the front lower needle bed FD by means of the yarn guide A.

[0052] Weft plain stitches of a tenth course are knitted every one stitch on the back lower needle bed BD by means of the yarn guide A.

[0053] Weft plain stitches of an eleventh course are knitted every one stitch in the ninth course by means of needles, not participating in alternate knitting, of the front lower needle bed FD by means of the yarn guide A.

[0054] Weft plain stitches of a twelfth course are knitted every one stitch in the tenth course by means of needles, not participating in alternate knitting, of the back lower needle bed BD by means of the yarn guide A.

[0055] Fully-knitted weft plain stitches of a thirteenth course are knitted on the front lower needle bed FD by means of the yarn guide A, and then needles on the back upper needle bed and the back upper needle bed are moved horizontally to transfer selected loops on the front lower needle bed leftwards by one stitch (one to eight stitches) by means of selected needles to form meshes on the upper surface layer.

[0056] Fully-knitted weft plain stitches of a fourteenth course are knitted on the back lower needle bed BD by means of the yarn guide A, then needles on the front upper needle bed and the back lower needle bed are moved horizontally to transfer selected loops on the back lower needle bed leftwards by one stitch (one to eight stitches) by means of selected needles to form meshes on the lower surface layer.

[0057] The whole fabric is cyclically knitted through the knitting method for 1-14 courses.

[0058] In this embodiment, the present invention added single-sided stitches after the support structure yarn by tuck stitch are knitted to lock the tuck structure , such that the support structure yarn will not puncture the surfaces of the fabric when the fabric is pressed. The four-needle bed computerized flat knitting machine is used for knitting the fabric, such that mesh structures are formed on the upper surface layer and the lower surface layer of the fabric under the condition that the upper surface layer and the lower surface layer of the three-dimensional fabric structure with an internal support structure are fully knitted, thus improving the breathability of the fabric.

[0059] In this embodiment, the fabric stands for 72 hours under a standard condition, namely under a temperature of 20° C. and a relative humidity of 65%, after being taken down from the knitting machine, and relevant parameters of the fabric are measured after deformation stress of yarns in the fabric is eliminated, wherein the thickness of the fabric is 8.24 mm, the surface density of the fabric is 0.12 g/cm.sup.2, and the breathability of the fabric tested on a YG461E-III fully-automatic breathability instrument with reference to GB/T5453:1997 (test of breathability of textile fabric) is 840 mm/s.

[0060] Although the preferred embodiments have been disclosed above, these preferred embodiments are not intended to limit the invention. Any skilled in the art may make different modifications and embellishments without departing from the spirit and scope of the invention. Thus, the protection scope of the invention should be the protection scope defined by the claims.