Weaving method of weft-backed jacquard fabric with color shading effect

Abstract

The present disclosure provides a weaving method of a weft-backed jacquard fabric with color shading effects and belongs to the technical field of weaving methods. In a single-warp and double-weft structure with a weft yarn arrangement ratio of Wefts A and Wefts B of 2:1, by designing two groups of face weaves and backing weaves and corresponding backed points and using a shaded strengthening method, two color shading effects of color shading of the Wefts A and mixed color shading of the Wefts A and the Wefts B of the fabric are achieved. A maximum number of shaded weaves is [R/N(6R−2J.sub.2−J.sub.1−3)+2], and a grade number of shaded color is less than or equal to the maximum number of the shaded weaves. The designed fabric meets the covering requirements and can be mass produced.

Claims

1. A weaving method of a weft-backed jacquard fabric with color shading effects, wherein the fabric is formed by interweaving 2 sets of weft yarns and 1 set of warp yarns, a Weft A and a Weft B have an arrangement ratio of 2:1, and the fabric is processed in the weaving method comprising the steps of: (1) constructing a structural model by, weaving the fabric by 1 set of the warp yarns and 2 sets of the weft yarns, wherein the warp yarns are in one color, the weft yarns are in two colors for the Weft A and the Weft B, the Weft A and the Weft B have the arrangement ratio of 2:1, the Weft A and the warp yarns are interwoven to form a Weft A weave, and the Weft B and the warp yarns are interwoven to form a Weft B weave, (2) selecting the Weft A weave and Weft B weave by, selecting the Weft A weave in a range of twill or satin, wherein a number of weave repeats is 2R×2R in a range between 4×4 and 48×48, selecting the Weft B weave in a range of derivative weaves of warp-separated plain, twill and satin, wherein a number of weave repeats is 2R×R in a range between 4×2 and 48×24, and where 2≤R≤24 and R is a positive integer; (3) designing face weave and backing weave and backed points by, when a face weft is the Weft B, selecting a warp-faced weave as a backing weave A.sub.L in the selection range of the Weft A weave; backed points Bj is set by reversing the A.sub.L and decomposing an obtained weave into weaves A.sub.LF1 and A.sub.LF2 according to odd and even wefts, then superimposing warp weave points of the A.sub.LF2 on the A.sub.LF1; and selecting one weave point for each weft from all weft weave points of the Bj as warp weave points to form a face weave B.sub.B based on meeting balanced interlacement, and when the face weft is the Weft A, selecting a warp-faced weave as a backing weave B.sub.L in the selection range of the Weft B weave; selecting one warp weave point for each weft from all warp weave points of the B.sub.L based on meeting balanced interlacement to form a decomposed weave A.sub.B1 or A.sub.B2 of a face weave A.sub.B, and then arranging and combining the A.sub.B1 and A.sub.B2 in 1:1 in a warp direction to obtain the face weave A.sub.B; and reversing the B.sub.L to obtain a reverse weave B.sub.LF, and then extending each weft of the reverse weave B.sub.LF one weft upwards in the warp direction or arranging and combining two B.sub.LF in 1:1 in the warp direction to set backed points Aj, (4) designing a shaded weave-database by designing the shaded weave-database of the face weave B.sub.B or A.sub.B by strengthening the weave points by means of warp-direction, weft-direction or oblique-direction transition without destroying the backed points Bj or Aj, (5) designing a compound structure by, determining that the weft yarns of the Weft A and the Weft B have the arrangement ratio of 2:1, drawing the backing weave A.sub.L at interweaving positions of the Weft A and the warp yarns, and drawing the face weave B.sub.B at interweaving positions of the Weft B and the warp yarns to obtain a database of the compound structure with the Weft B covering the Weft A, and determining that the weft yarns of the Weft A and the Weft B have the arrangement ratio of 2:1, drawing the face weave A.sub.B at the interweaving positions of the Weft A and the warp yarns, and drawing the backing weave B.sub.L at the interweaving positions of the Weft B and the warp yarns to obtain a database of the compound structure with the Weft A covering the Weft B, (6) verifying the backed points by, combining the most weft-faced and warp-faced weaves in the shaded weave-database with the backing weave respectively, wherein if both weaves are capable of meeting requirements that any one weft of the backing weave is capable of being covered by adjacent face weaves, combination of any one weave in the shaded weave-database with the backing weave is capable of meeting technical requirements of covering, (7) designing a digital pattern by designing a digital pattern with two color shading effects according to requirements, wherein the pattern is in two colors, and each color is designed with shaded color, and a grade number of the shaded color is less than or equal to a maximum number of shaded weaves, (8) designing a compound structure of the fabric by matching a shaded color in the two shaded colors of the digital pattern needing to reflect a pure color shading effect of the fabric with the database of the compound structure with the Weft A covering the Weft B, matching the shaded color needing to reflect a mixed color shading effect with the database of the compound structure with the Weft B covering the Weft A, processing by a computer, and replacing the shaded color of each grade with the weaves in the corresponding weave-database by a one-to-one correspondence method to form a compound structure diagram of the weft-backed jacquard fabric with color shading effects, and (9) weaving by, setting weft picking information on the obtained compound structure of the fabric, setting a warp and weft density, selecting one group of warp threads and two groups of colored weft threads, and then putting the warp threads and the weft threads into weaving.

2. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in step (3), when the face weft is the Weft B, a weave having the same number of weave repeats as the A.sub.LF1 or A.sub.LF2 and warp weave points not overlapping with that of the Bj is selected as the face weave B.sub.B, and a starting point displacement method is used to obtain (2R−J.sub.1) alternative face weaves having the same step number as the A.sub.LF1 or A.sub.LF2.

3. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in step (3), when the face weft is the Weft A, a weave having the same number of weave repeats as the B.sub.LF, the reverse weave of B.sub.L, and warp weave points not overlapping with that of the B.sub.LF is selected as the decomposed weave of the face weave A.sub.B, and a starting point displacement method is used to obtain (2R−J.sub.2) alternative decomposed weaves having the same step number as the B.sub.LF.

4. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 3, wherein in step (3), when the face weft is the Weft A, weaves with odd and even warps at starting point positions are selected from the alternative decomposed weaves and taken as the A.sub.B1 and A.sub.B2 respectively, then the A.sub.B1 and A.sub.B2 are arranged and combined in 1:1 in the warp direction to obtain the face weave A.sub.B, there are [2(R−J.sub.2J)(R−J.sub.2O)] such weaves in total, and J.sub.2J and J.sub.2O are respectively numbers of backed points at odd and even warps on one weft yarn when the Weft A is used as the face weft.

5. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in step (3), for the face weave B.sub.B and the backing weave A.sub.L when the Weft B is selected as the face weft, when the Weft A is designed as the face weft, the face weave B.sub.B and the backing weave A.sub.L are reversed as the backing weave B.sub.L and the face weave A.sub.B; and alternatively, for the face weave A.sub.B and the backing weave B.sub.L when the Weft A is selected as the face weft, when the Weft B is designed as the face weft, the face weave A.sub.B and the backing weave B.sub.L are reversed as the backing weave A.sub.L and the face weave B.sub.B.

6. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in step (2), a number of warp repeats of the Weft A weave is the same as that of the Weft B weave, and a number of weft repeats of the Weft A weave is twice that of the Weft B weave.

7. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in step (7), the maximum number of the shaded weaves is [R/N(6R−2J.sub.2−J.sub.1−3)+2], R is a number of weft repeats of the Weft B, N is an added value of weave points, and J.sub.1 and J.sub.2 are respectively numbers of backed points on one weft yarn in one weave repeat when the Weft B and the Weft A are used as the face weft.

8. The weaving method of a weft-backed jacquard fabric with color shading effects according to claim 1, wherein in one weave repeat, a weft float length or weft float number of the face weft is greater than that of the backing weft.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram of a structural model of a weft-backed jacquard fabric with color shading effects with an arrangement ratio of a Weft A and a Weft B of 2:1;

(2) FIG. 2 shows a backing weave A.sub.L when a face weft is the Weft B;

(3) FIG. 3 shows a reverse weave A.sub.LF of the backing weave A.sub.L when the face weft is the Weft B;

(4) FIG. 4 shows an odd-weft decomposed weave A.sub.LF1 of the A.sub.LF when the face weft is the Weft B;

(5) FIG. 5 shows an even-weft decomposed weave A.sub.LF2 of the A.sub.LF when the face weft is the Weft B;

(6) FIG. 6 shows backed points Bj when the face weft is the Weft B;

(7) FIG. 7 shows a series of alternative weaves of a face weave B.sub.B when the face weft is the Weft B;

(8) FIG. 8 shows the face weave B.sub.B when the face weft is the Weft B;

(9) FIG. 9 shows a backing weave B.sub.L when the face weft is the Weft A;

(10) FIG. 10 shows a reverse weave B.sub.LF of the backing weave B.sub.L when the face weft is the Weft A;

(11) FIG. 11 shows alternative decomposed weaves of a face weave A.sub.B when the face weft is the Weft A;

(12) FIG. 12 shows an odd-weft decomposed weave A.sub.B1 of the face weave A.sub.B when the face weft is the Weft A;

(13) FIG. 13 shows an even-weft decomposed weave A.sub.B2 of the face weave A.sub.B when the face weft is the Weft A;

(14) FIG. 14 shows the face weave A.sub.B when the face weft is the Weft A;

(15) FIG. 15 shows backed points Aj of the face weave A.sub.B when the face weft is the Weft A;

(16) FIG. 16 shows a shaded weave-database of the face weave B.sub.B when the face weft is the Weft B;

(17) FIG. 17 is a schematic diagram of increasing a maximum number of weaves between a first weave and a second weave in the shaded weave-database when the face weft is the Weft B (an added value of weave points is 1);

(18) FIG. 18 shows a shaded weave-database of the face weave A.sub.B when the face weft is the Weft A;

(19) FIG. 19 is a schematic diagram of increasing a maximum number of weaves between a first weave and a second weave in the shaded weave-database when the face weft is the Weft A (an added value of weave points is 1);

(20) FIG. 20 is a schematic structural diagram of the face weave B.sub.B and the backing weave A.sub.L combined in an order of ABA and a ratio of 2:1 from bottom to top in a warp direction when the face weft is the Weft B;

(21) FIG. 21 is a schematic structural diagram of the face weave A.sub.B and the backing weave B.sub.L combined in an order of ABA and a ratio of 2:1 from bottom to top in a warp direction when the face weft is the Weft A;

(22) FIG. 22 is a partial effect view of the weft-backed jacquard fabric with the color shading effect formed in the present disclosure; and

(23) FIG. 23 is a physical effect view of the weft-backed jacquard fabric with the color shading effect formed in the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(24) Taking designing a weft-backed jacquard fabric with color shading effects with an arrangement ratio of the Weft A and the Weft B of 2:1 by the Weft B weave with a number of weave repeats of 16×8 as an example, the implementation method of the present disclosure is described in detail.

(25) 1. In FIG. 1, the fabric is woven by 1 set of warp yarns and 2 sets of weft yarns. The warp yarns are in one color. The weft yarns are in two colors for a Weft A and a Weft B. The Weft A and the Weft B have an arrangement ratio of 2:1 (A in FIG. 1). The Weft A and the warp yarns are interwoven to form a Weft A weave. The Weft B and the warp yarns are interwoven to form a Weft B weave. Two combination methods for color expression are used in a single-warp and double-weft structure with the arrangement ratio of Weft A and Weft B of 2:1 (B and C in FIG. 1). When a face weft is the Weft A, the Weft A weave is a face weave and the Weft B weave is a backing weave. When the face weft is the Weft B, the Weft B weave is a face weave and the Weft A weave is a backing weave. A Weft B weave with a number of weave repeats of 16×8 is selected, and then a number of weave repeats of the Weft A weave is 16×16.

(26) 2. In FIG. 2 to FIG. 8, when the face weft is the Weft B, 16-satin with a step number of 10 with a starting point position at a lower left corner (warp, weft)=(1, 1) are selected as a backing weave A.sub.L. The backing weave A.sub.L is reversed to obtain a reverse weave A.sub.LF, and the reverse weave is 16-sateen with a step number of 5 with a starting point position of (1,1). Then the A.sub.LF is decomposed into decomposed weaves A.sub.LF1 and A.sub.LF2 according to odd and even wefts, and step numbers of the A.sub.LF1 and A.sub.LF2 are both 10. Finally, warp weave points of the A.sub.LF1 are superimposed on the A.sub.LF2 to obtain backed points Bj. Bj is a strengthened sateen with a number of weave repeats of 16×8, a starting point position of (1,1) and a step number of 10. One weave point is selected for each weft from all weft weave points of the Bj as warp weave points to form a face weave B.sub.B on the premise of meeting balanced interlacement. As a preferable solution, a step number of the face weave B.sub.B is selected the same as that of the A.sub.LF1 or A.sub.LF2. Starting from a starting point position at a lower left corner (warp, weft)=(1, 1), a weft-faced weave is designed according to a step number of 10 in a weave grid with a number of weave repeats of 16×8. Then, each time when the starting point is moved one weave point in a weft direction, one new weave is designed, and a series of weaves are designed until the starting point position is (16, 1). The weaves having warp weave points overlapping with that of the Bj are eliminated from this series of weaves, that is, the A.sub.LF1 and A.sub.LF2 with the starting point positions being (1,1) and (6,1) respectively are eliminated to obtain all alternative weaves of the face weave B.sub.B that meet requirements. There are (2R−J.sub.1)=16−2=14 alternative weaves in total. According to the requirements, a sateen with a number of weave repeats of 16×8, a step number of 10, and the starting point position at a lower left corner (warp, weft)=(9, 1) is selected as the face weave B.sub.B.

(27) 3. In FIG. 9 to FIG. 14, when the face weft is the Weft A, in order to improve the design efficiency, the reverse weave of the above face weave B.sub.B is selected as a backing weave B.sub.L, a satin with a starting point position at a lower left corner (warp, weft)=(9, 1), a number of weave repeats of 16×8, and a step number of 10 is selected as the backing weave B.sub.L. One warp weave point is selected for each weft from all warp weave points of the B.sub.L to form an odd-weft decomposed weave A.sub.B1 or an even-weft decomposed weave A.sub.B2 of a face weave A.sub.B on the premise of meeting balanced interlacement. As a preferable solution, the backing weave B.sub.L is reversed to obtain a reverse weave B.sub.LF. A step number of the decomposed weaves A.sub.B1 and A.sub.B2 is selected the same as that of the B.sub.LF. Starting from a starting point position at a lower left corner (warp, weft)=(1, 1), a weft-faced weave is designed according to a step number of 10 in a weave grid with a number of weave repeats of 16×8. Then, each time when the starting point is moved one weave point in the weft direction, one new weave is designed, and a series of weaves are designed until the starting point position is (16, 1). The weaves having warp weave points overlapping with that of the B.sub.LF are eliminated from this series of weaves, that is, the B.sub.LF with the starting point position of (9,1) is eliminated to obtain all alternative decomposed weaves of the face weave A.sub.B that meet requirements. There are (2R−J.sub.2)=(2×8−1)=15 alternative weaves in total. According to the requirements, weaves with starting point positions at a lower left corner (warp, weft)=(1, 1) and (5,1) are selected from the alternative decomposed weaves and taken as the A.sub.B1 and A.sub.B2, and the A.sub.B1 and A.sub.B2 are arranged and combined in 1:1 in a warp direction to obtain 16-sateen with a step number of 5 with a starting point position at a lower left corner (warp, weft)=(1, 1) as the face weave A.sub.B. There are [2(R−J.sub.2J)(R−J.sub.2O)]=2X(8−1)X(8−0)=112 face weaves designed by such method in total. In FIG. 16, each weft of the B.sub.LF is extended one weft upwards in the warp direction or two B.sub.LF are arranged and combined in 1:1 in the warp direction to obtain backed points Aj. Aj is a strengthened weft-faced 16-twill with a starting point position of (9,1) and a step number of 10.

(28) 4. In FIG. 16, when designing a shaded weave-database of the face weave B.sub.B, the face weave B.sub.B is taken as a primary weave, and various values between 1 and 8 can be selected for the weave point strengthening. For the convenience of presentation, this example uses N=R=8 point strengthening and weft-direction reinforcement. During strengthening, the weave points shall be continuous as far as possible. When encountering the backed points Bj, it skips without adding points. The shaded weave-database of (2R−J.sub.1)=2×8−2=14 shaded effects is formed. FIG. 17 shows the use of N=1 strengthening method (between the first and second weaves, and the rest is the same), a maximum number of shaded weaves available is [R(2R−1−J.sub.1)+1]=8×(2×8−1−2)+1=105.

(29) 5. In FIG. 18, when designing a shaded weave-database of the face weave A.sub.B, the face weave A.sub.B is taken as a primary weave, and various values between 1 and 16 can be selected for the weave point strengthening. For the convenience of presentation, this example uses N=2R=16 point strengthening and weft-direction reinforcement. During strengthening, the weave points shall be continuous as far as possible. When encountering the backed points Aj, it skips without adding points. The shaded weave-database of (2R−J.sub.2)=2×8−1=15 shaded effects is formed. FIG. 19 shows the use of N=1 strengthening method (between the first and second weaves, and the rest is the same), a maximum number of shaded weaves available is [2R(2R−1−J.sub.2)+1]=2×8×(2× 8−1−1)+1=225.

(30) 5. In FIG. 20, the Weft A and the Weft B are arranged in an order of ABA and a ratio of 2:1 from bottom to top in the warp direction. The backing weave A.sub.L is drawn at interweaving positions of the Weft A and the warp yarns. The face weave B.sub.B is drawn at interweaving positions of the Weft B and the warp yarns. After combination, a number of weave repeats is 16×24, and a compound structure diagram with the Weft B covering the Weft A is obtained. According to this method, each weave in the shaded weave-database of the face weave B.sub.B is combined with the backing weave A.sub.L to obtain a database of the compound structure with the Weft B covering the Weft A.

(31) 6. In FIG. 21, the Weft A and the Weft B are arranged in an order of ABA and a ratio of 2:1 from bottom to top in the warp direction. The face weave A.sub.B is drawn at interweaving positions of the Weft A and the warp yarns. The backing weave B.sub.L is drawn at interweaving positions of the Weft B and the warp yarns. After combination, a number of weave repeats is 16×24, and a compound structure diagram with the Weft A covering the Weft B is obtained. According to this method, each weave in the shaded weave-database of the face weave A.sub.B is combined with the backing weave B.sub.L to obtain a database of the compound structure with the Weft A covering the Weft B.

(32) 7. In FIG. 2 and FIG. 16, the most warp-faced and weft-faced weaves in the shaded weave-database of the face weave B.sub.B are combined with the backing weave A.sub.L for verification. If both compound structures are capable of meeting requirements that any one weft of the backing weave is capable of being covered by the adjacent face weaves, it indicates that combination of any one weave in the shaded weave-database with the backing weave is capable of meeting technical requirements of covering.

(33) 8. In FIG. 9 and FIG. 18, the most warp-faced and weft-faced weaves in the shaded weave-database of the face weave A.sub.B are combined with the backing weave B.sub.L for verification. If both compound structures are capable of meeting requirements that when the face weave expresses a color on the surface of the fabric, the backing weave has no effect on the color expression of the face weave, it indicates that combination of any one weave in the shaded weave-database with the backing weave is capable of meeting technical requirements of full covering.

(34) 9. A bitmap mode is used for the designed digital pattern. The subject matter is not limited. The pattern size, width and height are set to 2400 pixels. The pattern is in two colors. Each color is designed with shaded color, and a grade number of the shaded color is less than or equal to a maximum number of shaded weaves. The digital pattern with two color shading effects is formed. A maximum number of colors in the digital pattern is [R/N(6R−2J.sub.2−J.sub.1−3)+2]=8×(6× 8−2×1−2−3)+2=330.

(35) 10. A shaded color in the two shaded colors of the digital pattern needing to reflect a pure color shading effect of the fabric is matched with the database of the compound structure with the Weft A covering the Weft B. The shaded color needing to reflect a mixed color shading effect is matched with the database of the compound structure with the Weft B covering the Weft A. Processing is performed by a computer, and then the shaded color of each gray level is replaced with the weaves in the corresponding weave-database by a one-to-one correspondence method to form a compound structure diagram of the weft-backed jacquard fabric with the color shading effect with the arrangement ratio of the Weft A and the Weft B of 2:1. A partial effect view of the fabric is shown in FIG. 22.

(36) 11. Weft picking information is set as Weft A:Weft B=2:1 on the compound structure diagram of the 2:1 weft-backed jacquard fabric with the color shading effect. A warp and weft density is set as 114×84. One group of white warp yarns is selected as warp threads, one group of black weft yarns is selected as the Weft A, and one group of red weft yarns is selected as the Weft B. Then the 2:1 weft-backed jacquard fabric with the color shading effect can be produced. The surface of the fabric has two color shading effects of color shading of the Wefts A and mixed color shading of the Wefts A and the Wefts B. An effect view of the fabric is shown in FIG. 23.

(37) 12. The embodiments prove that as long as the backed points in the face weave are not destroyed, the fabric structure designed by the implementation method of the technical invention meets balanced interlacement and the covering requirements, is suitable for computer images of any subject matter, and can meet the technical requirements of mass production.