
How to overcome the technical difficulties and application prospects of double-sided jacquard fabrics?
What are the essential differences between the structural characteristics of double-sided jacquard fabric and ordinary jacquard?
Double-sided jacquard fabrics are significantly different from ordinary jacquard in terms of structural characteristics. Ordinary jacquards usually form patterns on one side of the fabric, and through the interweaving of warp and weft yarns, a concave and convex pattern is presented on the surface of the fabric. Double-sided jacquard fabrics use special looms and processes to make both sides of the fabric present clear, complete and interrelated patterns.
In terms of structure, double-sided jacquard fabrics often have a double-layer structure. For example, double-woven jacquard brocade uses a special jacquard loom to weave two interrelated layers of fabric at the same time, and the alternating weft and warp yarns form different patterns or colors on the front and back. The two layers can be connected through local joints or completely separated to form a hollow sandwich. This double-layer structure makes double-sided jacquard fabrics generally superior to ordinary jacquard fabrics in terms of thickness, texture and warmth retention.
From the perspective of the structure, ordinary jacquard can be divided into single-sided jacquard and double-sided jacquard, and single-color and multi-color. The front of the single-sided jacquard presents a specific structure, and the back may be floating threads, etc. In the double-sided jacquard, the sesame dot jacquard structure has different colored yarns on the back of the fabric in a loop, and the colors are arranged in a staggered manner; the air layer jacquard structure is that the selected color yarn is woven on the front needle bed, and the other color yarns are woven on the back needle bed, and an air layer is formed between the front and back loops of the fabric. The unique structural characteristics of the double-sided jacquard put forward higher requirements for yarn configuration, interweaving logic and production technology.
l Yarn configuration and interweaving logic analysis
Yarn configuration is crucial in double-sided jacquard fabrics. Since different or the same patterns are to be presented on both sides of the fabric, the yarns need to be carefully selected and matched. In terms of materials, a variety of fibers can be selected, such as mulberry silk and metal wire for high-end cheongsams and dresses, which can show a luxurious texture; cotton/linen as the base, with colored silk threads woven into parts, is often used in the new Chinese style. In modern improved styles, the combination of polyester and rayon can achieve a simulated silk effect and reduce costs; wool and polyester fiber blends can increase the stiffness of the fabric.
In terms of interweaving logic, the process of double-sided jacquard is more complicated. Taking a double-sided concave-convex jacquard curtain decorative fabric as an example, its weaving relies on a combination of a large jacquard machine with a middle opening that rises and falls at the same time to form an opening and a large jacquard machine with an upper opening that rises and falls alone to form an opening. The base fabric is made of the first warp yarn of the base fabric, the second warp yarn of the base fabric, etc., which are arranged in a circular manner in sequence and the first weft yarn and the third weft yarn are cyclically interwoven. The jacquard embellishment is based on the weaving of the base fabric. Through the up and down movement of the specific jacquard warp yarn and the base warp yarn, different weft yarns are put in to form a double-sided concave-convex jacquard effect. During weaving, the front of the fabric is woven according to the pattern requirements, and all the colored yarns in each weaving row on the back of the fabric are woven in sequence, forming a vertical stripe effect by different colored yarns. The more yarns involved in jacquard weaving, the more floating yarns there are between the front and back sides, the thicker the fabric, and the greater the weaving difficulty.
l Technical challenges of front and back pattern synchronization
Achieving synchronization of the front and back patterns of double-sided jacquard fabrics is a major technical challenge. During the production process, it is necessary to precisely control the various components of the loom to ensure that the patterns on the front and back sides are highly matched in position, shape and color. Any slight deviation may lead to inconsistent patterns and affect the quality of the fabric.
From the perspective of equipment, ordinary looms are difficult to meet the high-precision requirements of double-sided jacquard for pattern synchronization. They need to be equipped with specially designed jacquard looms and optimize the loom control system to achieve precise control of the movement of warp and weft yarns. In the pattern design stage, designers need to fully consider the characteristics of double-sided jacquard, use professional software for precise pattern design and layout, and ensure that the patterns on the front and back sides logically echo each other.
In actual production, even if the loom and design have reached a high level, they may still be disturbed by some factors, such as changes in yarn tension, wear of needles, etc., which may cause problems with pattern synchronization. Therefore, it is necessary to monitor the production process in real time and adjust the parameters in time to ensure the perfect synchronization of the front and back patterns of double-sided jacquard fabrics.
What are the key process bottlenecks in the current double-sided jacquard production?
l Precision requirements for electronic jacquard needle selection systems
The electronic jacquard needle selection system plays a core role in the production of double-sided jacquard, and its precision directly affects the clarity and accuracy of the pattern. Since double-sided jacquard needs to form complex patterns on both the front and back sides of the fabric, the electronic jacquard needle selection system has extremely high precision requirements.
As consumers' requirements for the complexity and fineness of double-sided jacquard fabric patterns continue to increase, the electronic jacquard needle selection system needs to be able to achieve more subtle needle selection movements. During the weaving process, the movement of each needle must be precisely controlled so that the yarn can be accurately placed on the corresponding needle according to the design requirements to form the ideal pattern. However, some current electronic jacquard needle selection systems may have inaccurate needle selection when faced with complex patterns, resulting in deviations, blurring or missing patterns, which seriously affects the quality of the fabric.
In order to meet the requirements of high precision, the electronic jacquard needle selection system needs to be continuously upgraded. On the one hand, it is necessary to improve the manufacturing precision of the hardware and reduce the errors between mechanical parts; on the other hand, it is necessary to optimize the software algorithm and enhance the system's processing ability and response speed for complex pattern data. In addition, the electronic jacquard needle selection system needs to be regularly maintained and calibrated to ensure that it always maintains high precision during long-term use.
l Effect of yarn tension control on double-sided effect
Yarn tension control is a key factor that cannot be ignored in the production of double-sided jacquard, and has an important impact on the double-sided effect. In the double-sided jacquard process, the yarn needs to shuttle between different parts of the loom and form the front and back patterns of the fabric according to a specific interweaving logic. If the yarn tension is unstable, it will cause a series of problems.
When the yarn tension is too high, the yarn may be overstretched, affecting its elasticity and strength, and even causing the yarn to break. On the fabric surface, it will show pattern deformation and inconsistent coil size, seriously affecting the appearance quality of double-sided jacquard fabrics. On the contrary, when the yarn tension is too low, the yarn may become loose during the weaving process, resulting in a loose fabric structure, unclear patterns, and difficulty in accurately matching the patterns on the front and back.
To achieve stable yarn tension control, the loom needs to be equipped with high-precision tension adjustment devices. These devices can adjust the yarn tension in real time according to the material, thickness and weaving process requirements of the yarn. At the same time, the operator also needs to have rich experience and be able to fine-tune the tension in time according to the actual performance of the yarn during the production process. In addition, there are also high requirements for the quality of the yarn itself, and the uniformity and stability of the yarn need to be ensured to reduce tension fluctuations caused by yarn quality problems.
How to improve the market competitiveness of double-sided jacquard through post-finishing technology?
l Compatibility of composite functional finishing (antibacterial/waterproof)
In today's market, consumers have an increasing demand for functional textiles. For double-sided jacquard fabrics, composite functional finishing, such as antibacterial and waterproof treatment, is an effective way to enhance its market competitiveness. However, when implementing these functional finishing, it is necessary to fully consider their compatibility with double-sided jacquard fabrics.
Taking antibacterial finishing as an example, different antibacterial agents may have different effects on the material and structure of double-sided jacquard fabrics. Some antibacterial agents may react chemically with the fibers in the fabric, causing the fabric to change color, feel worse, and even affect the clarity of the double-sided jacquard pattern. Therefore, when selecting antibacterial agents, a large number of tests are required to screen out products that have good antibacterial effects and are compatible with double-sided jacquard fabrics. At the same time, it is necessary to optimize the antibacterial finishing process and control parameters such as processing temperature, time, and antibacterial agent concentration to ensure that while giving the fabric antibacterial function, its original appearance and performance are not damaged.
Waterproof finishing also faces the problem of adaptability. There are many types of waterproofing agents, and their mechanisms of action and scope of application are different. For double-sided jacquard fabrics, it is necessary to choose a waterproofing agent that can be evenly attached to both sides of the fabric and does not affect the three-dimensional sense and breathability of the pattern. During the finishing process, attention should be paid to the coating method and amount of the waterproofing agent to avoid uneven waterproofing effect or affect the feel of the fabric. By reasonably selecting antibacterial/waterproofing agents and optimizing the finishing process, double-sided jacquard fabrics can add practical functions while maintaining their own characteristics, making them more competitive in the market.
l Technical solution for balancing weight and feel
Weight and hand feel are important factors that affect the quality and market acceptance of double-sided jacquard fabrics. Achieving a balance between the two is a key technical problem in the finishing process. Generally speaking, double-sided jacquard fabrics with a higher weight may give people a thick and textured feeling, but at the same time may also cause a hard hand feel; while the pursuit of a soft hand feel may reduce the weight of the fabric, affecting its durability and warmth retention properties.
In order to solve this problem, we need to start from multiple aspects. In terms of raw material selection, fibers with special properties, such as fine denier fibers, can be selected to ensure a certain weight and make the fabric feel softer. In the weaving process, the fabric structure is optimized, and the density and interweaving method of warp and weft yarns are reasonably adjusted to improve the relationship between the fabric feel and weight to a certain extent.
In the post-finishing process, appropriate softening agents and mechanical finishing methods are used. Softening agents can form a protective film on the fiber surface, reduce the friction between fibers, and thus make the fabric feel softer. At the same time, through mechanical pre-shrinking, calendering and other finishing methods, the flatness and feel of the fabric can be improved without significantly changing the gram weight. In addition, some new finishing technologies, such as plasma treatment, can be combined to micro-treat the fiber surface, effectively improving the feel of the fabric without affecting the gram weight. By comprehensively using these technical solutions, double-sided jacquard fabrics can achieve a better balance between gram weight and feel, meeting consumers' demand for high-quality fabrics.
How to tap the application potential of double-sided jacquard in high value-added fields?
l Structural demand matching in medical textiles
Medical textiles have special requirements for the performance and structure of fabrics. Double-sided jacquard fabrics have great application potential in this field due to their unique structural characteristics. In the medical environment, some medical products need to have good antibacterial, breathable, hygroscopic and specific structural support properties.
Double-sided jacquard fabrics can be reasonably designed to use yarns with antibacterial properties on one side for direct contact with wounds or skin, effectively inhibiting bacterial growth and reducing the risk of infection; and yarns with good breathability on the other side to ensure air circulation and improve patient comfort. For some medical textiles that need to provide structural support, such as bandages and protective gear, double-sided jacquard fabrics can form a support layer with a certain strength and elasticity through a special interwoven structure, which can not only meet the needs of fixing and protecting the injured part, but also adapt to human activities.
During the design process, it is necessary to work closely with medical professionals to gain an in-depth understanding of the specific structural requirements of medical textiles and to develop customized double-sided jacquard fabrics according to different application scenarios. By accurately matching the structural requirements of medical textiles, double-sided jacquard fabrics can play an important role in the medical field, increase product added value, and open up new market space.
l Conductive yarn embedding possibilities in smart clothing
With the development of science and technology, the field of smart clothing is gradually emerging, and the demand for fabrics with special functions is increasing. Double-sided jacquard fabrics provide the possibility of embedding conductive yarns, and are expected to show unique application value in the field of smart clothing.
Conductive yarns can connect clothing to electronic devices, so that clothing has intelligent functions such as body temperature monitoring, heart rate monitoring, and motion tracking. By embedding conductive yarns into double-sided jacquard fabrics, on the one hand, the double-layer structure of the double-sided jacquard fabric can be used to cleverly hide the conductive yarns in one layer, which does not affect the appearance of the fabric and ensures the stability and safety of the conductive yarns. On the other hand, by carefully designing the jacquard pattern and interweaving logic, the conductive yarns can form a specific circuit layout in the fabric, realizing effective signal transmission and accurate function realization.
In the process of embedding conductive yarns, some technical problems need to be solved. For example, how to ensure a good combination between conductive yarns and ordinary yarns to avoid breakage or poor contact during weaving and use; how to optimize the distribution of conductive yarns to ensure that the various functions of smart clothing can operate normally and are not affected by deformation such as fabric stretching and bending. By overcoming these technical difficulties, the combination of double-sided jacquard fabrics and conductive yarns will provide new ideas and solutions for the development of smart clothing, promote the field of smart clothing to a higher level, and further explore the application potential of double-sided jacquard fabrics in high value-added fields.
LATEST POST
Let’s create something amazing together
contact usDon't hesitate to contact when you need us!