Multi-filament yarns three-dimensional knitted fabric and system and method for manufacturing the same

Abstract

A multi-filament three-dimensional knitted fabric and a system and a method for manufacturing the same are provided. The multi-filament three-dimensional knitted fabric includes a surface layer structure, a bottom layer structure and a support structure. The support structure is disposed between the surface layer structure and the bottom layer structure, the support structure includes a plurality of first multi-filament yarns, each of the first multi-filament yarns connecting to the surface layer structure and the bottom layer structure, and each of the first multi-filament yarns having a specific denier and being composed of a plurality of fibers.

What is claimed is: 
     
         1 . A multi-filament three-dimensional knitted fabric, comprising:
 a surface layer structure;   a bottom layer structure; and   a support structure disposed between the surface layer structure and the bottom layer structure;   wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure.   
     
     
         2 . The multi-filament three-dimensional knitted fabric according to  claim 1 , wherein each of the surface layer structure and the bottom layer structure includes a non-elastic fiber and an elastic fiber; wherein the ratio of the non-elastic fiber to the elastic fiber is between 70:30 and 97:3. 
     
     
         3 . The multi-filament three-dimensional knitted fabric according to  claim 1 , wherein a thickness of the support structure is between 0.85 mm and 5 mm. 
     
     
         4 . The multi-filament three-dimensional knitted fabric according to  claim 1 , wherein a shrinkage of the multi-filament three-dimensional knitted fabric is between −5 and 0%. 
     
     
         5 . The multi-filament three-dimensional knitted fabric according to  claim 1 , wherein, a denier of the first multi-filament yarn is between 5 and 60 D. 
     
     
         6 . The multi-filament three-dimensional knitted fabric according to  claim 1 , wherein, the first multi-filament yarn is twisted from 2 to 75 yarns, and the denier of the yarn is between 0.5 to 30 D. 
     
     
         7 . The multi-filament three-dimensional knitted fabric according to  claim 6 , wherein the yarn is at least one selected from the group consisting of nylon, polyester fiber, polylactic acid fiber, polytrimethylene terephthalate fiber, and cellulose fiber. 
     
     
         8 . A system of manufacturing a multi-filament three-dimensional knitted fabric, comprising:
 a weaving device including a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric;   wherein the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees;   wherein the multi-filament three-dimensional knitted fabric includes:   a surface layer structure;   a bottom layer structure; and   a support structure disposed between the surface layer structure and the bottom layer structure;   wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure.   
     
     
         9 . A method of manufacturing a multi-filament three-dimensional knitted fabric, comprising:
 weaving at least one multifilament yarn into a weaving device to form the multi-filament three-dimensional knitted fabric; the multi-filament three-dimensional knitted fabric including:   a surface layer structure;   a bottom layer structure; and   a support structure disposed between the surface layer structure and the bottom layer structure;   wherein the support structure includes a plurality of first multi-filament yarns, and each of the first multi-filament yarns is connected to the surface layer structure and the bottom layer structure, and interlacingly form the support structure;   wherein the weaving device includes a yarn feeding unit, and the yarn feeding unit has a yarn feeder nozzle for interlacing and weaving at least one multifilament yarn into the multi-filament three-dimensional knitted fabric; wherein the multi-filament yarn passes through a yarn inlet of the yarn feeder nozzle at a yarn inlet angle between 40 and 55 degrees.   
     
     
         10 . The method according to  claim 9 , wherein, in the step of weaving at least one multifilament yarn into a weaving device to form the multi-filament three-dimensional knitted fabric, the length of a loop of yarn fed by the weaving device for a purl or a knit is between 450 and 700 cm, the length of a loop of yarn fed by the weaving device for a half stitch is between 1100 and 1800 cm, and a bind-off point of the purl has a scale ranging between 5 and 10, the bind-off point of the knit has a scale ranging between 5 and 10, and the bind-off point of the half stitch has a scale between 0 and 5.