US20160076177A1

US20160076177A1 - Warp knitting fabric expressing design pattern of jacquard texture on ground organization

Info

Publication number: US20160076177A1
Application number: US14/849,696
Authority: US
Inventors: Ki Won Kim; Hyeon Hak OH
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-09-16
Filing date: 2015-09-10
Publication date: 2016-03-17
Also published as: KR101468705B1

Abstract

A warp knitting including a ground organization and a pattern organization is provided. The ground organization includes a mesh forming portion knitted by a plurality of net organizations each having a specific shape, the net organizations being consecutively formed vertically and horizontally throughout an entire width in the longitudinal direction, and a pattern forming portion knitted in a predetermined area of the mesh forming portion where one desires to create the design pattern and overlapping the mesh forming portion to express a predetermined design pattern. The pattern organization is composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization and are integrally connected to each other to weave the fabric.

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to Korean Patent Application No 10-2014-0122629, filed Sep. 16, 2014, the entire contents of which is incorporated herein for all purposes by this reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention generally relates to a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization by a warp knitting machine. More particularly, the present invention relates to a wasp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, in which the design pattern is directly formed on the ground organization when a fiber structure of a warp knitting material is knitted in a factory, thus providing a fiber organization of the Jacquard texture, and in which a fabric is knitted such that the design pattern is primarily expressed on the ground organization, and a pattern organization is processed in post-processing to secondarily express the design pattern, thus enabling a design to be compositely expressed.
2. Description of the Related Art
Generally, a warp knitting fabric is a fiber structure having excellent elasticity, which is made by simultaneously and continuously supplying multiple warps in a longitudinal direction when a fabric is knitted by a Raschel lace machine, and consecutively interlocking loops with each other vertically and horizontally in the form of a net organization.
The fiber structure of the warp knitting fabric made by the Raschel lace machine is knitted by arranging multiple yarns in parallel, putting the yarns through needles in a warp direction, forming the warps in a coil form, forming loops into a net organization structure in a longitudinal direction, and vertically and horizontally interlocking the loops with each other. The fiber structure is formed by combining a ground organization that is composed of net organizations formed of a net structure having a specific shape with a pattern organization that is intended to express a design pattern during post-processing.
The term “ground organization” refers to a basic organization that is not changed in fiber organization structure forming a warp knitting material and constitutes a background of a pattern organization. This is an organization that is knitted throughout the warp direction while two or more warps form a predetermined shape of net structure in a longitudinal direction with respect to warps serving as a support column. The “pattern organization” is an organization that is interwoven with the ground organization and is capable of expressing a design pattern by post-processing. In other words, this is an organization that is woven by interlocking wefts in a transverse direction with the warps serving as the support column of the ground organization in a straight line or a curved line to cover and overlap a surface of the ground organization.
Such a warp knitting fabric is knitted while the fiber organization structure of the ground organization form loops in the net organization by the warps. The warp knitting fabric is advantageous in that air permeability is excellent due to the net organization structure, and elasticity and flexibility are good because the fiber structure has resilience, and delicate and various designs may be beautifully expressed in the pattern organization.
However, since the net organization structure is woven under tensions in a width direction and a longitudinal direction in the form of the loops having resilience and elasticity, contact points of the loops may be easily misaligned and deformed under the action of tension according to the shape of the net organization. Thus, the net organization structure is contracted in the longitudinal direction and the transverse direction of the fiber structure, so that it may be greatly deformed, for example, inclined or bent. Consequently, it is unstable in structure because the size and shape of the fiber structure is changed.
The warp knitting fabric having the above characteristics is increased in demand because it has functional and aesthetic elements unlike a general fabric, and is mainly used for women's clothing, such as women's underwear or lingerie, but its use has gradually spread from underwear to outdoor clothing or from women's clothing to men's clothing. At present, warp knitting fabric may be widely used without distinction of sex or age.
In addition, warp knitting fabric is used for home decorations such as curtains. As such, its use has become diversified. Further, in order to cope with a demand for a highly functional product having various functions, high quality by the expression of a high-class design, and application to various uses, a high value product meeting these requirements needs to be developed.
Here, the warp knitting fabric is the fiber structure that is knitted by the warps only in the longitudinal direction, and is formed by combining the ground organization composed of only the net organization that is the basic organization, with the pattern organization that forms the design pattern by the post-processing. Generally, the warp knitting fabric focuses on the formation of only the design pattern (motif) on the externally exposed pattern organization while forming the ground organization in the shape of the simple net organization, so that the expression of the design pattern on the ground organization is ignored. However, efforts are currently being concentrated on the development of the design pattern by surface processing of only the pattern organization.
That is, the design expression of the warp knitting fabric mostly focuses on only a process of realizing a pattern effect throughout the entire material by additionally expressing the design pattern over the pattern organization of the warp knitting fabric during the post-processing.
Therefore, the ground organization that is the basic organization of the warp knitting fabric is simply expressed in the net organization, and has limits in expressing various designs of the ground organization.
Technology has been developed to make a change in the ground organization having the shape of the simple net organization. That is, technology has been developed to change a design even in the ground organization, like the design pattern expressed on the pattern organization, by making complex unit organizations formed of various shapes of net organizations in one cycle to form a unit design and consecutively expressing various shapes of designs on the ground organization, so as to overcome the simplicity of the conventional ground organization formed of a single shape of net organization structure.
As the related art, Korean Patent No. 10-0970235 has been known as shown in FIGS. 1 to 3.
FIG. 1 is a photograph showing the state where a conventional actual warp knitting material is processed, and FIG. 2 is a photograph showing a ground organization 1 subjected to a burn-out process for completely removing a pattern organization of FIG. 1. This pertains to a warp knitting material that is knitted by combining the ground organization 1 with a pattern organization 2 by means of a general Raschel machine. Here, complex unit organizations A1, B1, C1 and D1, having different shapes of net organizations for the ground organization 1 of the material, are consecutively formed, thus expressing predetermined shapes of unit designs 10 and 20 in a longitudinal direction while constituting one cycle. Further, unit designs 10 and 20 in the shape of the net organization that are equal to or different from the aforementioned unit designs are compositely arranged and expressed in two or more rows in a transverse direction. The pattern organization 2 expresses a specific design pattern through a burn-out process and a dyeing process, thus making a change in ground organization that becomes a background of the pattern organization.
Unlike an existing ground organization having the shape of a simple net organization, this is intended to express the net organization in a complex shape using the different unit organizations A1, B1, C1 and D1 and the unit designs 10 and 20, as shown in FIG. 2. Therefore, it is possible to form the entire ground organization 1 that is visually expressed in the design of various net organization structures.
To be more specific, as shown in FIG. 3, net organizations having the same shape are grouped in the ground organization 1 that is the basic organization of the warp knitting fabric, and then are variously expressed for respective areas. The unit organizations A1, B1, C1 and D1 formed into four different shapes of net organizations are sequentially arranged to form one large rectangular unit design 10 or 20. The unit designs 10 and 20 are arranged to be consecutively and alternately repeated vertically and horizontally, thus creating the ground organization of the warp knitting fabric that is expressed in a large lattice pattern.
As such, the unit organizations A1, B1, C1 and D1 composed of various different shapes of net organizations and the unit designs 10 and 20 are expressed on the ground organization 1, thus allowing various shapes of base structures as well as an existing simple shape of base structure to be expressed and thereby providing the background of the design pattern formed on the pattern organization. This is expressed in harmony with various shapes of design patterns of the pattern organization 2 that is to be post processed, thus making a design look high-class and luxury.
This is advanced in that various net organization structures are expressed on the ground organization that is the basic organization providing the background of the pattern organization on which the design pattern is expressed, thus overcoming a previous simple net organization structure. However, there is no great development except for the diversification of the net organization structure.
In other words, the related art focuses on the design pattern of the pattern organization rather than the design of the ground organization as in the past. Further, the unit organizations A1, B1, C1 and D1 composed of the net organizations and the unit designs 10 and 20 are established only in the rectangular shape, so that upper, lower, left, and right edges are formed only in the straight-line shape and thereby the edges are angulated. Therefore, the ground organization is generally of a straight rectangular shape, so that the ground organization feels hard, and in addition a texture is not soft. Consequently, this organization still has limits in expression of various designs.
Moreover, due to a difference in tension between the unit organizations A1, B1, C1 and D1 composed of the net organizations and the unit designs 10 and 20 and a neighboring net-shaped organization structure, namely, a difference in tension between different net organization structures, interference may occur between the neighboring net organization structures and the net organization structures may be shrunk or deformed at a rectangular boundary, thus undesirably causing defective finishing.
Thus, the inventors of this invention made attempts to satisfy present needs, namely, high functionally, high-quality, diversification, and the diversification of a purpose, in order to overcome the problems where the ground organization is formed only in the shape of a monotonous net organization in the warp knitting material that is knitted by the Raschel lace machine. In other words, this invention overcomes the problem of limited expression of ground organization design.
The inventors have conducted research to solve the problems and have developed the warp knitting fabric expressing the design pattern of the Jacquard texture on the ground organization, in which, at the step of knitting the fiber organization of the warp knitting fabric by the Raschel lace machine in the factory, the net organization structure is formed on the ground organization that is the fiber organization of a warp knit, and simultaneously a separate design pattern is directly expressed on the ground organization, thus being capable of expressing a design with a high-quality jacquard texture while having the aesthetic effect and the three-dimensional effect, and the design pattern is directly and primarily expressed on the ground organization and the design pattern is secondarily expressed on the pattern organization at the post-processing step, thus being capable of expressing a complicated design pattern.
The term of a “mesh forming portion” that will be described below means a portion on the ground organization where a plurality of net organizations composed of specific shapes of net structures is grouped and expressed in a predetermined form.
The term of a “net organization group” means a group composed of a plurality of net organizations having the same shape of structure or an area where a plurality of net organizations having different shapes of structures is gathered in a predetermined form.
The term of a “pattern forming portion” means a portion which is formed on a predetermined area of the mesh forming portion of the ground organization and overlaps a surface of the organization of the mesh forming portion depending on a desired design pattern to express a predetermined design pattern.
The term of a “post-process” refers to a process for changing fiber organizations of the warp knitting fabric, for example, a burn-out process, a dyeing process, a coloring process, a foaming process, or the like that are carried out to form a design pattern on the pattern organization of the fabric or to make the design pattern be markedly expressed.
The term of the “burn-out” process refers to one type of post-process that is intended to fuse a processing surface other than a surface of the pattern organization where the design pattern is formed and to pierce a hole, thus allowing the structure of the ground organization that is the basic organization to be visible, in addition to making the design pattern of the pattern organization be markedly expressed.
The term of the “Jacquard” refers to a fabric in which a Pattern is incorporated in a patternless weave by a Jacquard loom. Jacquard weave is intended to precisely realize almost every kind of pattern or picture and express it luxuriously. Jacquard refers to a design having such a high-quality texture.
The term of a “patternless material” refers to a material that is produced by the post-process, namely, the dyeing process to express the warp knitting fabric with one or more colors.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and an object of the present invention is to provide a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, in which a mesh forming portion provided in the ground organization that is a basic fiber organization of the warp knitting fabric and is composed of net organizations, and a pattern forming portion overlapping the mesh forming portion to express a design pattern are knitted together, thus directly creating a design pattern on the ground organization and thereby being capable of expressing a high-class design of the Jacquard texture.
Another object of the present invention is to provide a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, in which a pattern forming portion for expressing a design overlaps a mesh forming portion when the warp knitting fabric is knitted, thus imparting a three-dimensional effect by the pattern forming portion that is exposed to an outside of the mesh forming portion while having an aesthetic effect, thus realizing a differentiated high-quality material.
A further object of the present invention is to provide a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, which is capable of fully expressing various patterns in each of the ground organization and a pattern organization when one desires to express the design pattern, and which is capable of compositely expressing both a design pattern expressed primarily in the ground organization and a secondary design pattern formed by processing the pattern organization during post-processing, so that a expression effect and a texture are excellent, thus realizing a high quality product.
Still another object of the present invention is to provide a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, which is configured to directly express a predetermined design pattern on a surface of the ground organization of a warp knitting fabric while a knitting operation is performed in a factory, thus reducing a processing cost for expressing the design pattern during the post-processing.
In order to achieve the above objects, according to one aspect of the present invention, there is provided a warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, the warp knitting fabric being produced by combining the ground organization with pattern organization, the ground organization being consecutively knitted vertically and horizontally in a longitudinal direction by a Raschel lace machine to form a net organization structure, the pattern organization being woven in a transverse direction to cover and overlap an entire surface of the ground organization and creating a design pattern during post-processing, wherein the ground organization includes a mesh forming portion knitted by a plurality of net organizations each having a specific shape, the net organizations being consecutively formed vertically and horizontally throughout an entire width in the longitudinal direction; and a pattern forming portion knitted in a predetermined area of the mesh forming portion where one desires to create the design pattern, and overlapping the mesh forming portion to express a predetermined design pattern, and the pattern organization is composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization and are integrally connected to each other to weave the fabric.
As is apparent from the above description, the present invention is advantageous in that, at a knitting step of forming an organization of a fiber structure in a factory, both a mesh forming portion and a pattern forming portion are simultaneously formed in a ground organization, so that a design pattern that is not changed in the shape of the organization structure is expressed from the ground organization that is a basic organization of a warp knitting fiber structure, thus allowing the texture and the shape of the design pattern to be expressed in a Jacquard texture and a high-quality design shape.
Further, the present invention is advantageous in that a ground organization and a pattern organization can compositely express a design pattern, so that the ground organization providing a background of the pattern organization subtly expresses the design pattern, and the pattern organization delicately and clearly expresses the design pattern, thus having a three-dimensional effect and an aesthetic effect while achieving harmony.
Furthermore, the present invention is advantageous in that a design is expressed by varying the kind and fineness of yarn used in a mesh forming portion and a pattern forming portion constituting a ground organization and in a pattern organization and then discriminately applying different kinds and finenesses of yarn through harmony and contrast of a design pattern, thus allowing various designs to be fully expressed without being limited to the shape of the design pattern and a line and thereby satisfying consumer demand.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a photograph showing a conventional actual warp knitting material;

FIG. 2 is a photograph showing an actual ground organization of the conventional warp knitting material;

FIG. 3 is an enlarged photograph represented by a box of FIG. 2;

FIG. 4 is a photograph showing an actual warp knitting fabric according to the present invention;

FIG. 5 is a photograph showing an actual object, with a pattern organization being partially burned-out to illustrate a ground organization formed in the warp knitting fabric according to the present invention;

FIG. 6 is a partially enlarged photograph showing the actual ground organization formed in the warp knitting fabric according to the present invention;

FIG. 7 is a view showing a design of the ground organization of the warp knitting fabric according to the present invention;

FIG. 8 is a photograph showing an actual object according to an embodiment of the present invention, with the fabric being partially burned out and dyed to illustrate the ground organization;

FIG. 9 is an enlarged photograph of FIG. 8 to illustrate a structure of a fiber organization of the warp knitting fabric according to the present invention;

FIG. 10 is a photograph showing an actual patternless material product that is made by dyeing the warp knitting fabric according to the present invention with one kind of color;

FIG. 11 is a photograph showing the actual material product that is subjected to post-processing, including a burn-out process and a dyeing process, according to an embodiment of the present invention; and

FIGS. 12 to 14 are photographs showing actual material products according to embodiments of the present invention, in which a burn-out process and a coloring process are alternately performed such that a ground organization of the warp knitting fabric is expressed in a horizontal band.

DESCRIPTION OF PREFERRED EMBODIMENTS

According to the present invention, provided is a warp knitting fabric produced by combining a ground organization with a pattern organization. The ground organization is consecutively knitted vertically and horizontally in a longitudinal direction by a Raschel lace machine to form a plurality of net organization structures, and the pattern organization is woven in a transverse direction to cover and overlap an entire surface of the ground organization and creates a design pattern during post-processing. The ground organization includes a mesh forming portion knitted by a plurality of net organizations each having a specific shape, the net organizations being consecutively formed vertically and horizontally throughout an entire width in the longitudinal direction, and a pattern forming portion knitted in a predetermined area of the mesh forming portion where one desires to create the design pattern and overlapping the mesh forming portion to express a predetermined design pattern. The pattern organization is composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization and are integrally connected to each other to weave the fabric.
Further, the pattern forming portion expressed by overlapping the mesh forming portion is expressed while occupying an area that is in a range of 50% to 80% of the ground organization.
Further, each of the net organizations of the ground organization has any one of shapes selected from a group including a rectangular shape, a diamond shape, a hexagonal shape and an octagonal shape.
The mesh forming portion is expressed by alternately arranging two neighboring net organizations having different shapes in a warp direction of the ground organization.
Further, the mesh forming portion is divided into net organization groups each having a plurality of net organizations at predetermined intervals in a longitudinal direction of the ground organization, the mesh forming portion being expressed in the shape of a transverse band by alternately arranging different net organization groups in two areas that are adjacent to each other in a vertical direction.
Further, the mesh forming portion is divided into areas of net organization groups each having a plurality of net organizations at predetermined intervals in a width direction of the ground organization, and is expressed in the shape of a longitudinal band by alternately arranging different net organizations in two areas that are adjacent to each other in a horizontal direction.
Further, yarn used in the mesh forming portion that forms the ground organization is polyester.
Furthermore, fineness of the yarn used in the mesh forming portion has PF 50 to 300 denier.
Further, yarn used in the pattern forming portion that forms the ground organization is polyester.
Furthermore, fineness of the yarn used in the pattern forming portion has DTY 75 to 450 denier or PF 50 to 300 denier.
Further, the design pattern expressed on the pattern forming portion of the ground organization is a flower pattern.
Furthermore, the wefts used in the pattern organization are any one selected from a group including cotton, rayon, acetate, silk or wool.
Further, the wefts used in the pattern organization are cotton, and fineness of the cotton is 40'S/2 or 30'S/2.
Hereinafter, the “warp knitting fabric expressing the design pattern of the Jacquard texture on the ground organization by the warp knitting machine” according to specific embodiments of the present invention having the above-described characteristics will be described in detail with reference to the accompanying drawings.
The present invention provides a warp knitting fabric produced by combining the ground organization with a pattern organization. The ground organization is consecutively knitted vertically and horizontally in a longitudinal direction by a Raschel lace machine to form a net organization structure. The pattern organization is woven in a transverse direction to cover and overlap an entire surface of the ground organization and creates a design pattern during post-processing. The ground organization 100 may include a mesh forming portion 110 knitted by a plurality of net organizations 111 each having a specific shape. The net organizations 111 are consecutively formed vertically and horizontally throughout an entire width in the longitudinal direction. The pattern forming portion 120 is knitted in a predetermined area of the mesh forming portion where one desires to create the design pattern, and overlaps the mesh forming portion 110 to express a predetermined design pattern. The pattern organization 200 is composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization 100 and are integrally connected to each other to weave the fabric.
As shown in FIGS. 4 to 6, the warp knitting fabric expressing the design pattern of the Jacquard texture on the ground organization according to the present invention is mainly composed of the ground organization 100 and the pattern organization 200.
The ground organization 100 is a basic organization that is not changed in organization structure forming the background of the pattern organization 200. The pattern organization 200 is formed of an organization having wefts that are woven in the transverse direction to cover and overlap the entire surface of the ground organization 100.
The ground organization 100 includes the mesh forming portion 110 and the pattern forming portion 120 to be clearly distinguished. The mesh forming portion 110 is formed of the net organizations 111 that are knitted throughout the entire surface in the longitudinal direction. The pattern forming portion 120 is formed to overlap with the mesh forming portion in an associated area depending on a predetermined area of the mesh forming portion where one desires to create the design pattern.
That is, when viewed from the thickness of the fabric, a portion where the mesh forming portion overlaps the pattern forming portion and a portion where the mesh forming portion does not overlap the pattern forming portion are separated from each other in the thickness direction in the ground organization. Further, the ground organization is located at an inside position while the pattern organization is located outside the ground organization.
As such, due to a thickness difference between the portion where the mesh forming portion does not overlap the pattern forming portion and the portion where the mesh forming portion overlaps the pattern forming portion, the mesh forming portion is located at the inside position and the pattern forming portion is located at the outside position, thus providing a three-dimensional effect. Further, the ground organization is shaped to be hidden in the pattern organization, so that the ground organization is subtly expressed at the inside position, and the pattern organization is clearly and delicately expressed at the outside position.
The mesh forming portion 110 is formed of the plurality of net organizations 111 each comprising the net structure of a predetermined shape, and is formed throughout the entire surface of the ground organization.
The net organizations 111 are minimum unit organizations of the ground organization, and are net structures that are equal to or different from each other in shape and are knitted in the warp direction all over the mesh forming portion. As seen from the photographs of FIGS. 4 to 14, the entire ground organization is knitted in the net organization of a single hexagonal shape. However, the shape or arrangement of the net organizations may vary.
It should be noted that the net organization may have any one of shapes including a rectangular shape, a diamond shape, a hexagonal shape or an octagonal shape.
In such a net organization, the plurality of net organizations is formed throughout the entire ground organization. Herein, for the convenience of description, a portion formed of a net organization group that is obtained by grouping the plurality of net organizations is referred to as the “mesh forming portion”.
The mesh forming portion 110 may be arranged in the ground organization in various net shapes of net organization groups. This may be selected to be in harmony with the design pattern to be expressed by the pattern forming portion 120. It is to be noted that the net organization groups are arranged to alternate with a neighboring net organization or net organizations.
As one arrangement shape of the mesh forming portion 110, different shapes of net organizations may be alternately arranged between two neighboring net organizations 111 in the warp direction of the ground organization.
The mesh forming portion 110 is divided into areas formed of the net organization groups each having the plurality of net organizations at predetermined intervals in the warp direction of the ground organization. Different shapes of net organizations are alternately arranged in two areas that are vertically adjacent to each other, so that they are grouped in the shape of a horizontal band.
Further, the mesh forming portion 110 is divided into areas formed of the net organization groups each having the plurality of net organizations at predetermined intervals in the width direction of the ground organization. Different shapes of net organizations are alternately arranged in two areas that are horizontally adjacent to each other, so that they are grouped in the shape of a vertical band.
The arrangement shape of the mesh forming portion 110 of such a ground organization that forms the background of the pattern organization 200 allows the design pattern on the pattern organization to be expressed variously and markedly.
Meanwhile, polyester may be used as yarn for forming the mesh forming portion 110, and the fineness of the used yarn may be selected to be in the range of PF 50 to 300 denier.
Here, if the fineness of polyester forming the mesh forming portion 110 is less than 50 denier, the yarn of the mesh forming portion is thin, thus causing the support strength to be weak. If the fineness of polyester is 300 denier or more, the design is crude and a product made of this polyester is worthless. In a design expressing method, the kind and fineness of yarn are main discriminative elements for expressing a design.
The pattern forming portion 120 is knitted in an area of a predetermined portion in the mesh forming portion 110 of the ground organization where one desires to create the design pattern to overlap the mesh forming portion 110 and thereby express the design pattern. Since the pattern forming portion 120 is directly formed as the ground organization from the beginning when the warp knitting fabric is knitted in a manufacturing factory, it is expressed to have a texture like luxurious Jacquard.
The yarn used in the pattern forming portion 120 forming the ground organization 100 may be knitted using polyester. Thus, the fineness of the used yarn may be selected from the range of DTY 75 to 450 denier or PF 50 to 450 denier.
Here, if the fineness of the yarn is less than DTY 75, the yarn of the pattern forming portion is thin, thus causing support strength to be weak. If the fineness of the yarn is 450 denier or more, the design is crude and a product made of this yarn is worthless.
The design pattern of the pattern forming portion 120 expressed in the ground organization 100 may have various shapes without being limited to a specific shape. However, the design pattern expressed on the pattern forming portion 120 is preferably a flower pattern. The reasons are because the flower pattern forming the background in the ground organization is beautiful and enhances the aesthetic effect.
Although the photographs shown in FIGS. 4 to 14 of the present invention take the flower pattern as the design pattern of the pattern forming portion, several shapes such as a snowflake are possible.
Meanwhile, the size of the area occupied by the pattern forming portion 120 that overlaps the mesh forming portion 110 occupies an area corresponding to 50 to 80% of the ground organization 100.
This allows the pattern forming portion 120 to be markedly expressed. Here, if an area occupying ratio of the pattern forming portion is less than 50%, a portion expressed in the pattern forming portion is relatively weakly expressed in the mesh forming portion. In contrast, if the area occupying ratio is 80% or more, the mesh forming portion that is the background of the pattern forming portion is weakly expressed and expression if the pattern forming portion is overly complicated.
The ratio of 65% is most preferable because it provides a harmonious expression. Here, the pattern forming portion 120 provides a subtle expression, while the pattern organization 200 provides a delicate and clear expression in various additional patterns by post-processing.
The pattern organization 200 are composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization 100 and are integrally connected to each other to weave the fabric.
The yarn used for the wefts of the pattern organization 200 may be woven using any one selected from a group including cotton, rayon, wool, acetate, or silk. The fineness of the yarn used in the pattern organization 200 is 40'S/2 or 30'S/2. In the case of the acetate or the silk, 120 to 360 denier is employed.
Here, if the fineness of cotton, rayon or wool is less than 40'S/2, the yarn of the pattern organization becomes thin, thus causing the support strength of the pattern organization to be weak. If the fineness is 30'S/2 or more, the design is crude and a product made of this yarn is worthless. If the fineness of acetate or silk is less than 120 denier, the yarn of the pattern organization becomes thin, thus causing the support strength of the pattern organization to be weak. If the fineness is 360 denier or more, the design is crude and a product made of this yarn is worthless.
According to the present invention, the warp knitting fabric is knitted using a filament PF as the yarn of the mesh forming portion 110, a stretch yarn DTY as the yarn of the pattern forming portion 120, and cotton as the wefts of the pattern organization 200. The reason why three kinds of yarn are used as such is because it is possible to enhance a contrast effect of yarn of different materials, namely, it is possible to cause a pattern to be clearly expressed by a difference in material, in addition to enabling the design to be markedly expressed throughout the entire fabric.
Particularly, during the post-processing of the warp knitting fabric, since PF is vulnerable to heat and thus is easily cured at the time of being heated, PF is used as the Yarn for the mesh forming portion 110 of the ground organization. On the other hand, since stretch yarn or DTY is heat-resistant and thus it is not cured at the time of being heated, DTY is preferably used for the pattern forming portion 120 that is knitted while overlapping the mesh forming portion. The reason is because it can clearly express the design pattern and is suitable to express a three-dimensional effect.
In other words, PF used for the mesh forming portion 110 is intended to form the net organization. Since PF is vulnerable to heat and thus is easily cured at the time of being heated during the post-processing, PF serves to fix the net organization. The pattern forming portion 120 uses the stretch yarn, that is, DTY. Since this is heat-resistant and is not cured even when DTY is heated at 180° C. in a tenter during the post-processing, it is preferable to apply DTY to the pattern forming portion 120.
Meanwhile, cotton used for the pattern organization 200 is a material that is easily removed in an organization other than the design pattern expressed in the pattern organization during the burn-out process, through chemical treatment, and is suitable to enhance the effect of expressing the design pattern through the exposed ground organization.
The pattern organization 200 is an organization that covers and overlaps the entire surface of the ground organization 100, and is compositely expressed by two design patterns, namely, a design pattern expressed in the ground organization 100 and an additional design pattern expressed in the pattern organization 200 by the post-processing (burning-out/dyeing/coloring, etc.). The design pattern of the ground organization 100 can be subtly expressed at the inside position, while the pattern of the pattern organization 200 can be clearly expressed at the outside position. Consequently, it is possible to express a high-class design.
For example, during the post-processing, such as the burning-out, a surface organization other than a design-pattern portion expressed in the pattern organization is fused, so that the cotton is eliminated and only the ground organization is expressed at the eliminated portion. As a result, while both the organizations of the mesh forming portion and the pattern forming portion expressed in the ground organization are subtly expressed, it is possible to clearly and markedly express the pattern in the pattern organization.
Meanwhile, when viewed from the entire thickness of the warp knitting fabric, a portion formed by causing the pattern forming portion to overlap the outside of the mesh forming portion and then causing the pattern organization to overlap the outside of the pattern forming portion, and a portion formed by causing only the pattern organization to overlap the outside of the mesh forming portion are present. As such, a double or triple overlap causes the pattern to be expressed while having a three-dimensional effect.
According to the present invention, it is possible to directly express a predetermined pattern on a surface of the ground organization that is not varied in organization structure while producing a warp knitting fabric. Therefore, when the design pattern of the ground organization is expressed, an expression effect and a texture are excellent, so that the Jacquard texture is realized and thereby a high quality is achieved. This is advantageous in that it can reduce a manufacturing cost as compared to the post-processing for expressing a specific pattern after the knitting has been performed.
Photographs of FIGS. 4 to 14 show the embodiments of the present invention. The embodiment relates to a warp knitting material that is manufactured as follows: the yarn of the mesh forming portion 110 of the ground organization uses polyester 75 PF, the pattern forming portion 120 is composed of stretch yarn DTY 150, and the weft 210 of the pattern organization uses 40'S/2 cotton.
FIGS. 8 and 9 show an embodiment of the present invention. This shows a warp knitting product obtained when the warp knitting fabric according to the present invention is subjected to the post-processing, such as the burn-out process and the dyeing process.
FIG. 10 shows another embodiment of the present invention. This shows a patternless material that is obtained by dyeing the warp knitting fabric according to the present invention with one kind of color.
As shown in FIG. 10, according to the present invention, yarn of the pattern forming portion 120 that directly forms a design pattern on the ground organization 100, the mesh forming portion 110, and the pattern organization 200 is knitted by different materials. Therefore, the contrast effect of the yarn of the different materials allows a person to feel a three-dimensional effect. In addition, a patternless material giving a two-tone pattern effect is available.
When the design pattern is usually expressed in the pattern organization 200, a work for precisely matching points of processing pattern plates with each other is required to maintain a position where the design of the material is formed in the post-processing factory. Since the present invention directly forms the design pattern on the ground organization and thereby expresses the design, the above-mentioned work is not required.
Thereby, in the case of the patternless material obtained by dyeing the warp knitting fabric according to the present invention with one color, it is possible to automatically secure the quality for the design pattern.
FIG. 11 shows a further embodiment of the present invention. In this embodiment, portions other than the flower pattern of the pattern organization of the warp knitting fabric according to the present invention are subjected to the burn-out process, thus expressing the design pattern.
This embodiment imparts a feeling as if the flower pattern of the pattern organization is floating off the ground organization, so that this shape is expressed while having the three-dimensional effect.
FIGS. 12 to 14 show other embodiments of the present invention. In these embodiments, the ground organization of the warp knitting fabric according to the present invention is alternately subjected to the burn-out process and the coloring process to be expressed in the horizontal band.
Meanwhile, when the design pattern expressed on the ground organization 100 and the design pattern expressed on the pattern organization 200 are compositely expressed, they may be expressed variously and aesthetically but may undesirably give a complex and disordered feeling. The pattern organization 200 may be expressed with a color in the shape of a line and a band. It is to be noted that design techniques, repetition, parallelism, continuation, crossing, gradation, conversion, radiation, concentration, contrast, rhythm, proportion, balance, emphasis or the like should be harmoniously connected with each other to effectively express a pattern.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
As described above, the warp knitting fabric of the present invention is mainly used for women's clothing, such as women's underwear or lingerie, but its use is gradually increasing from underwear to outdoor clothing or from women's clothing to men's clothing. The warp knitting fabric may be widely used without distinction of sex or age. In addition, the warp knitting fabric is used for home decorations such as curtains and the like. As such, its use has become diversified.
Further, the present invention copes with a demand for a highly functional product having various functions and a high quality expression of high-class design that is fashionable. That is, the invention is well worth considering as a strategic product having a high value.

Claims

What is claimed is:

1. A warp knitting fabric expressing a design pattern of a Jacquard texture on a ground organization, the warp knitting fabric being produced by combining the ground organization with a pattern organization, the ground organization being consecutively knitted vertically and horizontally in a longitudinal direction by a Raschel lace machine to form a net organization structure, the pattern organization being woven in a transverse direction to cover and overlap an entire surface of the ground organization and creating a design pattern during post-processing,

wherein the ground organization comprises:

a mesh forming portion knitted by a plurality of net organizations each having a specific shape, the net organizations being consecutively formed vertically and horizontally throughout an entire width in the longitudinal direction; and

a pattern forming portion knitted in a predetermined area of the mesh forming portion where one desires to create the design pattern, and overlapping the mesh forming portion to express a predetermined design pattern, and

the pattern organization is composed of wefts that cross in the transverse direction to cover and overlap the entire surface of the ground organization and are integrally connected to each other to weave the fabric.

2. The warp knitting fabric as set forth in claim 1, wherein the pattern forming portion expressed by overlapping the mesh forming portion is expressed while occupying an area that is in a range of 50% to 80% of the ground organization.

3. The warp knitting fabric as set forth in claim 1, wherein each of the net organizations of the ground organization has any one of shapes selected from a group including a rectangular shape, a diamond shape, a hexagonal shape or an octagonal shape.

4. The warp knitting fabric as set forth in claim 1, wherein the mesh forming portion is expressed by alternately arranging two neighboring net organizations having different shapes in a warp direction of the ground organization.

5. The warp knitting fabric as set forth in claim 1, wherein the mesh forming portion is divided into net organization groups each having a plurality of net organizations at predetermined intervals in the warp direction of the ground organization, the mesh forming portion being expressed by alternately arranging different net organization groups in two areas that are adjacent to each other in a vertical direction.

6. The warp knitting fabric as set forth in claim 1, wherein the mesh forming portion is divided into net organization groups each having a plurality of net organizations at predetermined intervals in a width direction of the ground organization, the mesh forming portion being expressed by alternately arranging different net organization groups in two areas that are adjacent to each other in a horizontal direction.

7. The warp knitting fabric as set forth in claim 1, wherein yarn used in the mesh forming portion forming the ground organization comprises polyester.

8. The warp knitting fabric as set forth in claim 7, wherein fineness of the polyester used in the mesh forming portion has PF 50 to 300 denier.

9. The warp knitting fabric as set forth in claim 1, wherein yarn used in the pattern forming portion forming the ground organization comprises polyester.

10. The warp knitting fabric as set forth in claim 9, wherein fineness of the polyester used in the pattern forming portion has DTY 75 to 450 denier or PF 50 to 300 denier.

11. The warp knitting fabric as set forth in claim 1, wherein the design pattern expressed on the pattern forming portion of the ground organization comprises a flower pattern.

12. The warp knitting fabric as set forth in claim 1, wherein yarn used in the wefts of the pattern organization comprises any one selected from a group including cotton, rayon, wool, acetate or silk.

13. The warp knitting fabric as set forth in claim 12, wherein the wefts are the cotton, and fineness of the cotton is 40'S/2 or 30'S/2.