Warp-knitted integrated plush fabric and preparation method thereof

Abstract

A warp-knitted integrated plush fabric and preparation method thereof are provided. The plush fabric includes a first plush layer, a second plush layer, and a connecting layer; wherein the first plush layer includes a front guide bar underlap layer formed by processing the front guide bar underlaps; the connecting layer, from the first plush layer to the second plush layer, successively includes a middle guide bar underlap layer, a back guide bar underlap layer, a middle guide bar loop layer, and a front guide bar loop layer, each layer being formed by interknitting the corresponding middle guide bar underlaps, back guide bar underlaps, middle guide bar loops, and front guide bar loops successively; the second plush layer includes a back guide bar loop layer, a back guide bar underlap layer, or a combination of both. The preparation method includes the steps of yarn warping, on-machine knitting, and dyeing and finishing.

What is claimed is: 
     
         1 . A warp-knitted integrated plush fabric, comprising a first plush layer, a second plush layer, and a connecting layer located between the first plush layer and the second plush layer;
 wherein the first plush layer comprises a front guide bar underlap layer formed by processing front guide bar underlaps;   the connecting layer, from the first plush layer to the second plush layer, successively comprises a middle guide bar underlap layer, a first back guide bar underlap layer, a middle guide bar loop layer, and a front guide bar loop layer, each of the middle guide bar underlap layer, the first back guide bar underlap layer, the middle guide bar loop layer, and the front guide bar loop layer being formed by interweaving corresponding middle guide bar underlaps, first back guide bar underlaps, middle guide bar loops, and front guide bar loops successively;   the second plush layer comprises a back guide bar loop layer, a second back guide bar underlap layer, or a combination layer of the back guide bar loop layer and the second back guide bar underlap layer, wherein the back guide bar loop layer is formed by processing back guide bar loops, the second back guide bar underlap layer is formed by processing second back guide bar underlaps, and the combination layer is formed by processing the back guide bar loops and the second back guide bar underlaps; and   a knitting process is performed with the following amounts of warp let off:   a front guide bar: wherein an actual amount of warp let off used is 0.9-1.1 times a calculated amount of warp let off;   a middle guide bar: wherein the actual amount of warp let off used is 0.85-0.95 times the calculated amount of warp let off; and   a back guide bar: wherein the actual amount of warp let off used is 1.5-3 times the calculated amount of warp let off.   
     
     
         2 . The warp-knitted integrated plush fabric according to  claim 1 , wherein the front guide bar utilizes an N+1 needle closed tricot stitch, with a Lapping Notation being: 1−0/N−(N+1)//(N≥15); or
 the front guide bar utilizes two N+1 needle and P+1 needle closed tricot stitches in a same direction, with the Lapping Notation being: 1−0/N−(N+1)//(N≥15) and 1−0/P−(P+1)//(P≤10), respectively. 
 
     
     
         3 . The warp-knitted integrated plush fabric according to  claim 1 , wherein the middle guide bar utilizes an L+1 needle closed tricot stitch, with a Lapping Notation being: L−(L+1)/1−0//(1≤L≤3); or
 the middle guide bar utilizes two L+1 needle closed tricot stitches in opposite directions, with the Lapping Notation being: L−(L+1)/1−0//(1≤L≤3) and 1−0/L−(L+1)//(1≤L≤3), respectively. 
 
     
     
         4 . The warp-knitted integrated plush fabric according to  claim 1 , wherein the back guide bar utilizes an M+1 needle open tricot stitch, with a Lapping Notation being: 0−1/(M+1)−M//(2≤M≤5); or
 the back guide bar utilizes an M needle weft insertion stitch, with the Lapping Notation being: M−M/0−0//(2≤M≤5); or 
 the back guide bar utilizes the M+1 needle open tricot stitch, with the Lapping Notation being: (M+1)−M/0−1//(2≤M≤5); or 
 the back guide bar utilizes two M+1 needle open tricot stitches in opposite directions, with the Lapping Notation being: 0−1/(M+1)−M//(2≤M≤5) and (M+1)−M/0−1//(2≤M≤5), respectively; or the back guide bar utilizes two M needle weft insertion stitch in opposite directions, with the Lapping Notation being: 0−0/M−M//(2≤M≤5) and M−M/0−0//(2≤M≤5), respectively; or the back guide bar utilizes one M+1 needle open tricot stitch and one M needle weft insertion stitch, with the Lapping Notation being: 0−1/(M+1)−M// and 0−0/M−M//(2≤M≤5), respectively. 
 
     
     
         5 . The warp-knitted integrated plush fabric according to  claim 1 , wherein the front guide bar utilizes a 75-300D polyester draw texturing yarn (DTY) low-elasticity yarn with a round cross-section, with a denier per filament (DPF) ranging from 0.52-1.04D, or a 75-300D polyester fully drawn yarn (FDY) filament with a flat cross-section, with the DPF ranging from 1.04−4.16D;
 the middle guide bar utilizes a 50-100D polyester FDY or a DTY conventional polyester filament; 
 the back guide bar utilizes the 75-300D polyester DTY low-elasticity yarn with the round cross-section, with the DPF ranging from 0.52-1.04D; or one selected from the group consisting of a 75-300D polyester sea-island yarn, a solution-dyed polyester filament, a lyocell filament, and a silk. 
 
     
     
         6 . A method for preparing the warp-knitted integrated plush fabric according to  claim 1 , comprising the following steps:
 S 100 : determining yarn raw materials for knitting and warping yarns using a selected warping machine;   S 200 : using a warp knitting machine equipped with greater than or equal to three guide bars, dividing the guide bars into three groups for knitting of the front guide bar, the middle guide bar, and the back guide bar respectively, and performing on-machine knitting:   A, yarn setting: front guide bar: 1 in 1 out; middle guide bar: full setting; back guide bar: full setting;   B, knitting: the knitting process is performed with the following amounts of warp let off:
 front guide bar: the actual amount of warp let off used is 0.91.1 times the calculated amount of warp let off; 
 middle guide bar: the actual amount of warp let off used is 0.850.95 times the calculated amount of warp let off; 
 back guide bar: the actual amount of warp let off used is 1.53 times the calculated amount of warp let off; 
 drawing density used in knitting ranges from 13 to 20 cpc, and machine operating speed ranges from 1500 to 2200 rpm; 
 S 300 : perform dyeing and finishing processes on a knitted greige to obtain the warp-knitted integrated plush fabric. 
   
     
     
         7 . The method according to  claim 6 , wherein in the step S 200 , before the on-machine knitting, a back guide bar tension compensator is adjusted, that is, a tension rod of the back guide bar tension compensator is extended forward by 15-35 cm; and the back guide bar tension compensator is equipped with a tension spring having a tension sensitivity of not less than 0.1 cN. 
     
     
         8 . The method according to  claim 6 , wherein in the step S 100 , a method for knitting and warping the yarns is performed as follows:
 the front guide bar: using an SGZ400D intelligent computer-controlled warping machine, with a warping beam specification: Φ21×21″; a number of warp patterns: 293 ends; a number of warping beams: 8; a warping speed: 1200 rpm; and a warping tension: 8-9 cN;   the middle guide bar: using an SGZ300D computer-controlled high-speed warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1500 rpm; and the warping tension: 5-6 cN; and   the back guide bar: using the SGZ400D intelligent computer-controlled warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1200 rpm; and the warping tension: 8-9 cN.   
     
     
         9 . The method according to  claim 6 , wherein in the step S 300 , the dyeing and finishing processes comprise:
 performing greige back side pre-setting, back side napping or brushing, and first back side shearing on a side of the second plush layer in sequence to obtain a processed second plush layer side;   performing greige front side pre-setting, front side napping, and front side polishing on a side of the first plush layer in sequence to obtain a processed first plush layer side; and   performing dyeing, softening and washing, drying, and hot blowing on the processed first plush layer side and the processed second plush layer side in sequence to obtain a resulting first plush layer side and a resulting second plush layer side; then performing front side polishing and shearing on the resulting first plush layer side, and performing second back side shearing on the resulting second plush layer side to obtain a processed greige; and finally, the processed greige undergoes tumbling and fabric rolling.   
     
     
         10 . The method according to  claim 6 , wherein during the knitting process, for a knitting yarn, a charge-coupled device (CCD) camera is configured to capture images of yarn feeding and detect a vibration of the warp knitting machine;
 each single yarn is identified using image recognition, and according to a feeding distance of each single yarn and detected warp knitting machine vibration data, a vibration transmission of each single yarn is simulated and analyzed using a simulation technology, and obtaining vibration data of each point of each single yarn within the feeding distance; wherein the vibration data comprises a vibration amplitude;   using a machine vision recognition technology to perform image preprocessing on captured real-time images, wherein each single yarn is identified through the image recognition, and vibration data of a corresponding single yarn is combined to perform image analysis of each single yarn, and obtaining yarn diameter data of each point of a real-time feeding single yarn;   wherein the yarn diameter data is compared with upper and lower limit threshold values of a corresponding single yarn diameter, and when the yarn diameter data deviates from a range defined by the upper and lower limit threshold values, an alarm signal is generated.   
     
     
         11 . The method according to  claim 6 , wherein in the warp-knitted integrated plush fabric, the front guide bar utilizes an N+1 needle closed tricot stitch, with a Lapping Notation being: 1−0/N−(N+1)//(N≥15); or
 the front guide bar utilizes two N+1 needle and P+1 needle closed tricot stitches in a same direction, with the Lapping Notation being: 1−0/N−(N+1)/(N≥15) and 1−0/P−(P+1)/(P≤10), respectively. 
 
     
     
         12 . The method according to  claim 6 , wherein in the warp-knitted integrated plush fabric, the middle guide bar utilizes an L+1 needle closed tricot stitch, with a Lapping Notation being: L−(L+1)/1−0//(1≤L≤3); or
 the middle guide bar utilizes two L+1 needle closed tricot stitches in opposite directions, with the Lapping Notation being: L−(L+1)/1−0//(1≤L≤3) and 1−0/L−(L+1)//(1≤L≤3), respectively. 
 
     
     
         13 . The method according to  claim 6 , wherein in the warp-knitted integrated plush fabric, the back guide bar utilizes an M+1 needle open tricot stitch, with a Lapping Notation being: 0−1/(M+1)−M//(2≤M≤5); or
 the back guide bar utilizes an M needle weft insertion stitch, with the Lapping Notation being: M−M/0−0//(2≤M≤5); or 
 the back guide bar utilizes the M+1 needle open tricot stitch, with the Lapping Notation being: (M+1)−M/0−1//(2≤M≤5); or 
 the back guide bar utilizes two M+1 needle open tricot stitches in opposite directions, with the Lapping Notation being: 0−1/(M+1)−M//(2≤M≤5) and (M+1)−M/0−1//(2≤M≤5), respectively; or the back guide bar utilizes two M needle weft insertion stitch in opposite directions, with the Lapping Notation being: 0−0/M−M//(2≤M≤5) and M−M/0−0//(2≤M≤5), respectively; or the back guide bar utilizes the M+1 needle open tricot stitch and the M needle weft insertion stitch, with the Lapping Notation being: 0−1/(M+1)−M// and 0−0/M−M//(2≤M≤5), respectively. 
 
     
     
         14 . The method according to  claim 6 , wherein in the warp-knitted integrated plush fabric, the front guide bar utilizes a 75-300D polyester DTY low-elasticity yarn with a round cross-section, with a DPF ranging from 0.52-1.04D, or a 75-300D polyester FDY filament with a flat cross-section, with the DPF ranging from 1.04−4.16D;
 the middle guide bar utilizes a 50-100D polyester FDY or a DTY conventional polyester filament; 
 the back guide bar utilizes the 75-300D polyester DTY low-elasticity yarn with the round cross-section, with the DPF ranging from 0.52-1.04D; or one selected from the group consisting of a 75-300D polyester sea-island yarn, a solution-dyed polyester filament, a lyocell filament, and a silk. 
 
     
     
         15 . The method according to  claim 11 , wherein in the step S 200 , before the on-machine knitting, a back guide bar tension compensator is adjusted, that is, a tension rod of the back guide bar tension compensator is extended forward by 15-35 cm; and the back guide bar tension compensator is equipped with a tension spring having a tension sensitivity of not less than 0.1 cN. 
     
     
         16 . The method according to  claim 12 , wherein in the step S 200 , before the on-machine knitting, a back guide bar tension compensator is adjusted, that is, a tension rod of the back guide bar tension compensator is extended forward by 15-35 cm; and the back guide bar tension compensator is equipped with a tension spring having a tension sensitivity of not less than 0.1 cN. 
     
     
         17 . The method according to  claim 13 , wherein in the step S 200 , before the on-machine knitting, a back guide bar tension compensator is adjusted, that is, a tension rod of the back guide bar tension compensator is extended forward by 15-35 cm; and the back guide bar tension compensator is equipped with a tension spring having a tension sensitivity of not less than 0.1 cN. 
     
     
         18 . The method according to  claim 14 , wherein in the step S 200 , before the on-machine knitting, a back guide bar tension compensator is adjusted, that is, a tension rod of the back guide bar tension compensator is extended forward by 15-35 cm; and the back guide bar tension compensator is equipped with a tension spring having a tension sensitivity of not less than 0.1 cN. 
     
     
         19 . The method according to  claim 11 , wherein in the step S 100 , a method for knitting and warping the yarns is performed as follows:
 the front guide bar: using an SGZ400D intelligent computer-controlled warping machine, with a warping beam specification: ¢21×21″; a number of warp patterns: 293 ends; a number of warping beams: 8; a warping speed: 1200 rpm; and a warping tension: 8-9 cN;   the middle guide bar: using an SGZ300D computer-controlled high-speed warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1500 rpm; and the warping tension: 5-6 cN; and   the back guide bar: using the SGZ400D intelligent computer-controlled warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1200 rpm; and the warping tension: 8-9 cN.   
     
     
         20 . The method according to  claim 12 , wherein in the step S 100 , a method for knitting and warping the yarns is performed as follows:
 the front guide bar: using an SGZ400D intelligent computer-controlled warping machine, with a warping beam specification: Φ21×21″; a number of warp patterns: 293 ends; a number of warping beams: 8; a warping speed: 1200 rpm; and a warping tension: 8-9 cN;   the middle guide bar: using an SGZ300D computer-controlled high-speed warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1500 rpm; and the warping tension: 5-6 cN; and   the back guide bar: using the SGZ400D intelligent computer-controlled warping machine, with the warping beam specification: Φ21×21″; the number of warp patterns: 588 ends; the number of warping beams: 8; the warping speed: 1200 rpm; and the warping tension: 8-9 cN.