tensioning device

Abstract

Aspects herein relate to a tensioning device for a strand on a knitting machine. The tensioning device includes a mounting plate that can be positioned between a strand source and a feeder bar. The mounting plate supports a first pulley, a second pulley, and a weighted third pulley that is movable relative to the first and second pulleys. By passing the strand over the first pulley, under the third pulley, and over the second pulley, additional tension can be added to the strand by the weight of the third pulley.

Description

Technical Field

[0001] This article relates in various aspects to a tensioning device for yarn strands on a knitting machine, a knitting machine having a yarn strand tensioning device, and a method for providing lateral tension to yarn strands on a knitting machine. Background Technology

[0002] Traditional knitting machines (including plain knitting machines) typically have some type of lever arm to provide lateral tension to individual yarn strands. This lateral tension may be needed to tighten slack portions of the yarn strands when they are not fed into the knitting machine. This type of lever arm works quite well when using lighter or smaller diameter yarn strands. However, the traditional lever arm method does not work well with heavier or larger diameter yarn strands. Attached Figure Description

[0003] The following is a detailed description of examples from various aspects of this article, with reference to the accompanying drawings:

[0004] Figure 1 The illustration shows a partial perspective view of a knitting machine according to various aspects of this article, with the tensioning device in an untensioned state;

[0005] Figure 2 The diagram illustrates the relationship between various aspects of this article and... Figure 1 A similar view, but the tensioning device is in a tensioned state;

[0006] Figure 3 The diagram illustrates the relationship between various aspects of this article and... Figure 1 A similar view shows an alternative path for the strands of wire through the tensioning device;

[0007] Figure 4 The illustration shows a side perspective view of the tensioning device according to various aspects of this article;

[0008] Figure 5 The diagram illustrates the various aspects based on this article. Figure 4 A perspective view of the tensioning device from opposite sides;

[0009] Figure 6 The diagram illustrates the various aspects based on this article. Figure 4 A front perspective view of the tensioning device; and

[0010] Figure 7 The diagram illustrates a flowchart of an example method for providing lateral tension to yarn strands on a knitting machine, based on various aspects of this article. Detailed Implementation

[0011] The subject matter of the present application is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps in order to achieve the same goals, in conjunction with other presently known or future technologies. Moreover, although the terms "step" and / or "block" might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein commensurate with the purposes of the disclosure. The term "about" or "substantially" with reference to a measurement means within ±10% of the indicated value, unless otherwise indicated.

[0012] Knitting machines are now used to manufacture portions of garments or portions of footwear, such as footwear uppers. In some constructions, it can be desirable to utilize one or more strands that are heavier in weight or larger in diameter than strands conventionally used in such constructions. However, use of these heavier weight or larger diameter strands can create problems in the knitting process and in the finished product.

[0013] At a high level, aspects herein relate to a knitting machine that can include a source of strands, a feeder bar, and at least one strand extending from the source of strands and through the feeder bar. The knitting machine can also include a tensioning device for the strand located between the source of strands and the feeder bar. The tensioning device adds tension to the strand when the knitting machine is not actively feeding the strand. As one example, the tensioning device adds tension at a turn when a feeder for the knitting machine changes a direction of knitting. The added tension also mitigates any sudden impact tension on the yarn at the turn. The added tension results in tighter stitches in the knitted material to produce a better looking garment with sharper edges. The tensioning device allows for better knitting results with a wide array of different strand diameters and strand weights, such as, for example, interlocking brio yarns. In another example, the tensioning device improves the "take-up" of interlocking Lilly yarns. In example aspects, the tensioning device also includes a mounting arm coupled to an upper end of a mounting plate of the tensioning device. The mounting arm couples the tensioning device to a rail on the knitting machine. Aspects herein also relate to a tensioning device for a strand, where a portion of the strand extends on a knitting machine between a feeder bar and a source of strands. The tensioning device includes a mounting plate having an upper end and a lower end and a first side and a second side that is farther from the feeder bar than the first side. The tensioning device also includes a first pulley coupled to the mounting plate near the upper end and the second side of the mounting plate, a second pulley spaced apart from the first pulley and coupled to the mounting plate near the upper end and the first side of the mounting plate, and a third pulley. In some aspects, the third pulley is movably coupled to the mounting plate between the first pulley and the second pulley and is positioned at least partially below the first pulley and the second pulley. The movable coupling of the third pulley to the mounting plate allows the third pulley to move in a direction between the upper end of the mounting plate and the lower end of the mounting plate. The strand can travel over the first pulley, below the third pulley, and over the second pulley, where the weight and the movability of the third pulley provide a downward force to increase tension on the strand.

[0014] In example aspects, the mounting plate includes a vertical slot having a bottom end near the lower end of the mounting plate and extending to a top end spaced apart from the bottom end. A first rod extends through the vertical slot on the mounting plate, and the third pulley is coupled to the first rod. As such, the first rod and the third pulley are vertically movable relative to the mounting plate within the vertical slot. The weight of the rod and third pulley combination provides a downward force to increase tension on the strand. In example aspects, the first pulley and the second pulley are each rotatably coupled to the mounting plate, and the third pulley is rotatably coupled to the first rod, allowing the strand to move over and / or under each of the pulleys.

[0015] In example aspects, the mounting plate also has a front side and a back side. The tensioning device can have a first bearing coupled to the first rod and abutting the front side of the mounting plate and a second bearing coupled to the first rod and abutting the back side of the mounting plate. The first bearing and the second bearing provide controlled movement of the first rod within the vertical slot.

[0016] In example aspects, the first rod is removably coupled to the third pulley. The tensioning device can also include other rods having different weights that are interchangeable with the first rod to allow selective changing of the tension on the strand.

[0017] In some aspects, the tensioning device can also include a fourth pulley coupled to the mounting plate below the first pulley and near the second side of the mounting plate. The fourth pulley can be used as needed to increase the tension and / or friction on the strand as it moves through the tensioning device. The strand can then travel under the fourth pulley, over the first pulley, under the third pulley, and over the second pulley. In some aspects, the fourth pulley is adjustably coupled to the mounting plate such that the position of the fourth pulley relative to the mounting plate is adjustable to further adjust the friction experienced by the strand and / or the tension on the strand.

[0018] Example aspects of the present disclosure also include a method of providing lateral tension to a strand on a knitting machine. In aspects, the method can include causing the strand to travel over a first pulley, under a weighted third pulley that is vertically movable relative to the first pulley, and over a second pulley. A method of providing tension in accordance with some aspects of the present disclosure can also include adding additional weight to the weighted third pulley to increase the tension on the strand. In some aspects, the additional weight added to the weighted third pulley is based on at least one of a weight of the strand or a diameter of the strand. In some aspects, the method can also include, prior to causing the strand to travel over the first pulley, causing the strand to travel under a fourth pulley to further increase the friction and / or tension on the strand. In still other aspects, the method of providing tension can also include adjusting a spacing between the first pulley and the fourth pulley to provide additional tension to the strand.

[0019] Figures 1 to 3 A tensioning device 100 coupled to a knitting machine 200 is shown. The knitting machine 200 can be used to knit (such as flat knit) any type of flat knit garment. In some aspects, the knitting machine 200 can be used to knit a shoe upper for an article of footwear. When used in conjunction with the knitting machine 200, the tensioning device 100 can be effective to reduce slack in a strand of yarn traveling through the knitting machine, thereby improving the quality and / or appearance of the resulting knit fabric. This can be particularly useful when using a heavier weight and / or larger diameter strand of yarn in the knit fabric. For simplicity, only portions of the knitting machine 200 are shown. In some aspects, the knitting machine 200 is a flat knitting machine as shown, having two needle beds angled relative to each other (e.g., thereby forming a V-shaped bed) andone or more rails (e.g., rails 202) extending above and along the length of the needle beds. However, the tensioning device 100 can be used on other types of knitting machines as desired. As shown, the tensioning device 100 is coupled to a guide rail 202 of a knitting machine 200. The guide rail 202 extends between an upper member 166 and a lower member 168 of the tensioning device 100. The upper member 166 and the lower member 168 are connected to one another by a connector 170. The knitting machine generally has a plurality of strands of knitted material (e.g., yarns and fibers made from various natural or synthetic materials such as cotton, nylon, TPU, polyester, polyurethane, or carbon, etc.) that are fed from a source of strands (e.g., spools, bobbins, threads, cables, etc.), as indicated schematically by arrows 204.

[0020] As Figure 1 shown, the strands 206 travel around a first guide 208, through a tension arm 210, around a second guide 212, and through a feeder bar 214. The tension arm 210 eliminates some slack in the strands 206 when the strands 206 are not actively fed through the knitting machine 200. In some cases, strands having a heavier weight or a larger diameter (e.g., a diameter greater than 1 mm) can not function as desired in this arrangement, and slack in these heavier weight or larger diameter strands cannot be effectively eliminated using only the tension arm 210. The strands 206 can have a configuration of, for example, a multifilament yarn, a filament (e.g., a monofilament yarn), a wire, a rope, a webbing, a cable, or a chain. In some cases, the strands have a heavier weight or a larger diameter. In some aspects, the yarns 206 can have a diameter from about 0.1 mm to about 20 mm. The tensioning device 100 introduces increased tension to the heavier weight and / or larger diameter strands (i.e., as shown by the strands 216 in Figure 1 which effectively eliminates undesirable slack, thereby improving the quality and / or appearance of the resulting knitted fabric.

[0021] Figure 1 The strands 216 are depicted in a fed state by the knitting machine 200. In this strand feeding state, the tension arm 210 is in an intermediate position (not adding additional tension to the strands 216). In some aspects, prior to being fed through the feeder bar 214, the strands 216 are fed after the guide 212, over the first pulley 126, under the third pulley 138, and over the second pulley 132. Additionally, in the strand feeding state depicted in Figure 1 the strands 216 are fed through the knitting machine 200. In some aspects, the strands 216 are fed through the knitting machine 200 in a manner that causes the third pulley 138 to be pulled to the top end 122 (or near the top end 122) of the vertical slot 120 in the mounting plate 102 of the tensioning device 100.

[0022] Figure 2The image depicts the yarn strand 216 in a state where the knitting machine 200 is not actively feeding the yarn strand 216 (non-feeding state). In this non-feeding state, the tension arm 210 is in an engaged position (adding additional tension to the yarn strand 216) and operates to pull the yarn strand (e.g., ...). Figure 2 (As shown, pull to the right). It has been found that for heavier or larger diameter strands, the added tension provided by tension arm 210 alone may not be effective in eliminating the required slack in the strand 216 in the non-feeding state. Tensioning device 100 provides added tension in strand 216, thereby resulting in a more ideal knitted structure of the final fabric or product, with more uniform loop size and tension. In operation, Figure 2 In the non-feeding state depicted, when gravity pulls the third pulley 138 downward within slot 120, the weight of the third pulley 138 adds tension to the strand 216. In some respects, the third pulley 138 can be moved to the bottom end 124 (or near the bottom end 124) of slot 120. Additional weight can be added to the third pulley 138, thereby adding additional tension to the strand 216 in the non-feeding state. This can be achieved by selecting an appropriately weighted lever (such as those described below) connected to the third pulley 138. Figure 6 The first lever 142 or the second lever 154 shown can adjust the amount of tension added to the strand 216 as needed to accommodate different weights and / or diameters of the strand 216. Although only two levers are depicted, it should be understood that other levers may also be used.

[0023] Figure 3 An alternative travel path of the thread 216 through the tensioning device 100 is depicted. For example... Figure 3 As shown, to add additional tension and / or friction to the strand 216, the strand 216 may first travel under the fourth pulley 158, and then over the first pulley 126, under the third pulley 138, and over the second pulley 132. In some respects, the fourth pulley 158 is movable on the mounting plate 102 (e.g., within a vertical slot or an arcuate slot). The movement of the fourth pulley 158 can, for example, apply additional tension to the strand 216 by adding friction. In some respects, the fourth pulley 158 may be biased into a desired position within a slot on the mounting plate 102 using a spring. In some respects, when the added tension is applied by the tensioning device 100, the strand 216 may not travel through the tension arm 210.

[0024] Figures 4 to 6Perspective views of one side of the tensioning device 100 are depicted from different angles. The tensioning device 100 includes a mounting plate 102. The mounting plate 102 has an upper end 104 spaced apart from a lower end 106. Similarly, the mounting plate 102 has a first side 108 spaced apart from a second side 110. In some aspects, the mounting plate 102 has a generally rectangular main portion and may also have a tab 112 extending along the upper end 104 at the first side 108. In other aspects, the mounting plate 102 may also have a tab 114 extending downward from the lower end 106 along the second side 110. However, it should be understood that the mounting plate 102 can have any of a variety of shapes, and other shapes are also contemplated herein. Additionally, the mounting plate 102 has a front side 116 and a back side 118. Figure 4 and Figure 5 As can be seen, in some aspects, the mounting plate 102 also has a slot 120 extending from the front side 116 through the mounting plate 102 to the back side 118. In an example aspect, the slot 120 is vertically oriented on the mounting plate 102, with the top end 122 near the upper end 104 of the mounting plate and the bottom end 124 near the lower end 106 of the mounting plate. In some aspects, a series of stops spaced between the top end 122 and the bottom end 124 along the slot 120 can be used to adjust or limit the amount of tension applied to the yarn (such as strand 216). Using stops more towards the top end 122 is more effective in limiting tension than using stops more towards the bottom end 124. In some aspects, stops that are adjustable in length along the slot 120 can be used. The stops can move between a first position allowing movement of the third pulley 138 (described below) and a second position preventing movement of the third pulley 138. In other words, stops can be used to effectively shorten the length of the slot 120. Mounting plate 102 can be made of lightweight, strong materials, and in some respects, mounting plate 102 is made of flat metal material, but other materials can also be used and other materials are also envisioned herein.

[0025] In an example, the tensioning device 100 also includes a plurality of pulleys connected to the mounting plate 102. For example... Figure 4As best seen, the first pulley 126 is coupled to the mounting plate 102 near the upper end 104 and the second side 110. The first pulley 126 may be generally cylindrical and may include a groove 128. The groove 128 may extend around the entire circumference of the first pulley 126, or it may extend only partially around the first pulley 126, such as extending along the top of the first pulley 126. In some aspects, the shape and size of the groove 128 are designed to accommodate strands 216 of yarn for use on the knitting machine 200. In some aspects, the first pulley 126 is rotatably coupled to the mounting plate 102. This rotatable coupling may be achieved using a pin 130 that extends through a central hole in the first pulley 126 and is coupled to the mounting plate 102. In some aspects, the pin 130 may be a shouldered bolt that passes through the mounting plate 102, although the pin 130 may take other forms to achieve the rotatable coupling.

[0026] In this example, the second pulley 132 is also connected to the mounting plate 102. The second pulley 132 is connected to the mounting plate 102 near the upper end 104 and the first side 108, and in some aspects, the second pulley 132 may be connected to the tab 112 of the mounting plate 102. In some aspects, the second pulley 132 may have the same overall configuration as the first pulley 126. For example... Figure 4 As shown, for example, the second pulley 132 has a groove 134, the shape and size of which can be designed to accommodate strands 216 of yarn for the knitting machine 200. Similar to the first pulley 126, the groove 134 can extend around the entire circumference of the second pulley 132, or it can extend only partially around the second pulley 132, such as extending along the top of the second pulley 132. In some aspects, the second pulley 132 is rotatably coupled to the mounting plate 102. This rotatable coupling can be achieved by a pin 136 extending through a central hole in the second pulley 132 and coupled to the mounting plate 102. In some aspects, the pin 136 can be a shouldered bolt that passes through the mounting plate 102, but other constructions can also be used to achieve the rotatable coupling.

[0027] like Figure 4 and Figure 6As best seen in the image, the tensioning device 100 includes a third pulley 138, similar to the first pulley 126 and the second pulley 132, which may include a groove 140. The groove 140 may extend around the entire circumference of the third pulley 138, or it may extend only partially around the third pulley 138, such as along the bottom of the third pulley 138. In some aspects, the third pulley 138 is coupled to a first rod 142. In some aspects, the third pulley 138 is rotatably coupled to the first rod 142, such as by a pin 144, which may be a shoulder bolt or other construction allowing for a rotatable connection. The first rod 142 extends through a slot 120 on the mounting plate 102, such that the combination of the first rod 142 and the third pulley 138 is vertically movable relative to the mounting plate 102 within the slot 120. One or more first bearings 146 may be coupled to the first rod 142 and positioned to engage the front surface 116 of the mounting plate 102. Similarly, one or more second bearings 148 may be coupled to the first rod 142 and positioned to also engage the back surface 118 of the mounting plate 102. In some aspects, the back surface 118 may include a recessed area 149 (e.g., Figure 5 (As shown) to further guide the second bearing 148. (As shown) Figure 5 and Figure 6 As shown, the first bearing 146 and the second bearing 148 can be connected to the first side 150 of the first rod 142, the second side 152 of the first rod 142, or both the first side 150 and the second side 152 of the first rod 142.

[0028] like Figure 6 As shown, the tensioning device 100 may further include a second rod 154. In some aspects, the second rod 154 has a different weight than the first rod 142. For example, the second rod 154 may be made of a different material than the first rod 142, or in other instances, the second rod 154 may be made of the same material as the first rod 142, but may be larger. Figure 6 As shown, the second rod 154 includes a mounting hole 156. The mounting hole 156 may be threaded, allowing the first bearing 146 and the second bearing 148 to be removed from the first rod 142 and reconnected to the second rod 154. In this way, the first rod 142 can be interchanged with the second rod 154 (and vice versa), allowing the weight connected to the third pulley 138 to be varied as needed. Similarly, any other number of rods with different weights can be used, interchangeable with the first rod 142, to adjust the tension on the strand 216 by adjusting the weight connected to the third pulley 138 as needed.

[0029] like Figure 6As shown, in some aspects, the fourth pulley 158 is also coupled to the mounting plate 102 near the lower end 106 and the second side 110. The fourth pulley 158 can be selectively used to increase the tension and / or friction on the yarn strand 216 as it moves through the tensioning device 100. For example, the fourth pulley 158 may be coupled to the tab 114 of the mounting plate 102. In some aspects, the fourth pulley 158 may have the same overall configuration as the first pulley 126. For example, as shown, the fourth pulley 158 may have a groove 160 whose shape and size are designed to accommodate the yarn strand 216 for use on the knitting machine 200. The groove 160 may extend around the entire circumference of the fourth pulley 158, or only partially around the fourth pulley 158, such as extending along the bottom and sides of the fourth pulley 158. In some aspects, the fourth pulley 158 is rotatably coupled to the mounting plate 102. The rotatable connection can be achieved using a pin 162 that extends through a central hole in the fourth pulley 158 and connects to the mounting plate 102. In some cases, the pin 162 is a shouldered bolt that inserts into the mounting plate 102, but other constructions can also be used to achieve the rotatable connection. In some cases, the fourth pulley 158 is typically movable relative to the mounting plate 102 (e.g., within a vertical or arcuate slot). In other cases, the fourth pulley 158 can be connected to a biasing member (such as a spring) to actively bias the fourth pulley 158 within a slot in the mounting plate 102 to add additional friction and / or tension to the yarn strands. Any of the aforementioned pulleys (first pulley 126, second pulley 132, third pulley 138, and fourth pulley 158) can be interchanged to accommodate different types of yarn, wherein the corresponding grooves (grooves 128, 132, 140, and 160) are sized to accommodate yarns in use. As described above, the range of motion of any of the pulleys can also be changed to adjust the tension (e.g., limiting the range of motion of the third pulley 138 and / or the fourth pulley 158). Additionally, the weight of any of the pulleys (first pulley 126, second pulley 132, third pulley 138, and fourth pulley 158) or arms (such as the first lever 142 and / or the second lever 154) can be changed to adjust the tension on the yarn. In some aspects, the tensioning device 100 can be interchanged when using yarns of different sizes and / or weights.

[0030] like Figure 6 As shown, in some aspects, the tensioning device 100 may also include a mounting arm 164. This mounting arm 164 connects the tensioning device 100 to the knitting machine 200, as referenced above. Figures 1 to 3 The mounting arm 164 includes an upper member 166 spaced apart from the lower member 168. The upper member 166 and the lower member 168 are connected together by a connector 170 (e.g., screw, bolt, shoulder bolt, etc.). Figure 5As best seen in the middle, the lower member 168 includes a series of mounting holes 172. The mounting holes 172 are threaded to receive bolts 174 (e.g., ...). Figure 4 and Figure 6 As can be seen in the image, bolt 174 can be inserted through the corresponding hole in mounting plate 102 and pass through mounting hole 172.

[0031] Figure 7 A flowchart illustrates an example method 700 for providing lateral tension to strands of yarn being knitted or embedded in garment using a knitting machine (such as knitting machine 200). Method 700 can be performed using a tensioning device (such as tensioning device 100). In step 710, method 700 includes traveling the strands of yarn over a first pulley, which may have features similar to the aforementioned first pulley 126. In step 712, method 700 includes traveling the strands of yarn under a weighted third pulley, which may have features similar to the aforementioned third pulley 138, and then in step 714, traveling the strands of yarn over a second pulley, which may have features similar to the aforementioned second pulley 132. In step 712, in some respects, the weighted third pulley is located below the first and second pulleys, and the third pulley is arranged to allow vertical movement. When the knitting machine does not actively feed the yarn through the knitting machine (such as when the yarn feeder changes direction during a turn), the weight of the third pulley adds tension to the yarn, thus increasing the tension on the yarn and eliminating at least some slack that may be present in the yarn. In some respects, as shown at step 716, the yarn can travel around a fourth pulley (which may have features similar to the aforementioned fourth pulley 158) after the first pulley and before the third pulley. In some respects, the fourth pulley is arranged to move to adjust the tension or friction imposed on the yarn as it moves through the knitting machine.

[0032] The following clauses represent exemplary aspects of the concepts envisioned herein. Any of the following clauses may be combined in multiple dependent ways to be subordinate to one or more other clauses. Furthermore, any combination of subordinate clauses (clauses that are expressly subordinate to preceding clauses) may be combined while remaining within the scope of the aspects envisioned herein. The following clauses are illustrative in nature and not restrictive.

[0033] Clause 1. A tensioning device for at least one strand of yarn, a portion of which extends on a knitting machine between a yarn feeder bar and a strand source, the tensioning device comprising: a mounting plate having an upper end and a lower end, a first side and a second side, the second side being spaced further away from the yarn feeder bar than the first side; a first pulley coupled to the mounting plate; a second pulley coupled to the mounting plate and spaced apart from the first pulley; and a third pulley having a first weight, the third pulley being movably coupled to the mounting plate between the first pulley and the second pulley and being positioned at least partially below the first pulley and the second pulley, wherein the movable coupling of the third pulley to the mounting plate allows the third pulley to move in a direction between the upper end and the lower end of the mounting plate, wherein the at least one strand of yarn is capable of traveling above the first pulley, below the third pulley and above the second pulley, wherein the first weight of the third pulley provides a downward force to increase the tension on the at least one strand of yarn.

[0034] Clause 2. The tensioning device according to Clause 1, wherein the first pulley is connected to the mounting plate near the upper end of the mounting plate and near the second side of the mounting plate.

[0035] Clause 3. The tensioning device according to any one of Clauses 1 to 2, wherein the second pulley is connected to the mounting plate near the upper end of the mounting plate and near the first side of the mounting plate.

[0036] Clause 4. The tensioning device according to any one of Clauses 1 to 3, wherein the mounting plate includes a vertical slot having a bottom end near the lower end of the mounting plate and extending to a top end spaced apart from the bottom end; the tensioning device further includes a first rod extending through the vertical slot on the mounting plate, the first rod having a second weight, wherein a third pulley is coupled to the first rod, and wherein the first rod and the third pulley are vertically movable relative to the mounting plate within the vertical slot, wherein the first weight of the third pulley and the second weight of the first rod provide a downward force to increase the tension on the at least one strand.

[0037] Clause 5. The tensioning device according to any one of Clauses 1 to 4 further includes a series of stops extending along the slot between the bottom end of the slot and the top end of the slot, the stops being movable between a first position allowing the third pulley to move along the slot and a second position preventing the third pulley from moving along the slot, wherein in the first position, the stops effectively shorten the length of the slot.

[0038] Clause 6. The tensioning device according to any one of Clauses 1 to 5 further includes a stop capable of being positioned along the slot between the bottom end of the slot and the top end of the slot, the stop being movable between a first position allowing the third pulley to move along the slot and a second position preventing the third pulley from moving along the slot, wherein in the first position, the stop effectively shortens the length of the slot.

[0039] Clause 7. The tensioning device according to any one of Clauses 1 to 6, wherein the first pulley and the second pulley are rotatably connected to the mounting plate, and wherein the third pulley is rotatably connected to the first rod.

[0040] Clause 8. A tensioning device according to any one of Clauses 1 to 7, wherein the mounting plate has a front and a back, the tensioning device further comprising at least a first bearing coupled to the first rod and adjacent to the front and at least a second bearing coupled to the first rod and adjacent to the back, wherein at least the first bearing and the second bearing provide controlled movement of the first rod within the vertical slot on the mounting plate.

[0041] Clause 9. The tensioning device according to any one of Clauses 1 to 8, wherein the first rod is removably coupled to the third pulley, the tensioning device further comprising a second rod having a third weight different from the second weight of the first rod, and being interchangeable with the first rod to allow selective change of the tension on the at least one strand.

[0042] Clause 10. The tensioning device according to any one of Clauses 1 to 9 further includes a mounting arm connected to the upper end of the mounting plate, the mounting arm facilitating the connection of the tensioning device to a guide rail on the knitting machine.

[0043] Clause 11. The tensioning device according to any one of Clauses 1 to 10 further includes a fourth pulley, the fourth pulley being below the first pulley and connected to the mounting plate at a position near the second side of the mounting plate, wherein the at least one strand is capable of traveling above the first pulley, around the fourth pulley, below the third pulley, and above the second pulley.

[0044] Clause 12. The tensioning device according to any one of Clauses 1 to 12, wherein any of the first pulley, the second pulley, the third pulley, and the fourth pulley has a groove, and wherein the width of the groove can be selected based on the diameter of the strand.

[0045] Clause 13. The tensioning device according to any one of Clauses 1 to 12, wherein the fourth pulley is adjustablely connected to the mounting plate such that the position of the fourth pulley relative to the mounting plate is adjustable.

[0046] Clause 14. A knitting machine comprising: a yarn source; a yarn feeder bar; at least one yarn strand extending from the yarn source and passing through the yarn feeder bar; and a tensioning device for the at least one yarn strand located between the yarn source and the yarn feeder bar, the tensioning device comprising: a mounting plate having an upper end, a lower end, a first side, and a second side, the second side being spaced further from the yarn feeder bar than the first side; a first pulley coupled to the mounting plate; a second pulley coupled to the mounting plate and spaced apart from the first pulley; and a third pulley having a weight, the third pulley being movably coupled to the mounting plate between the first pulley and the second pulley and being positioned at least partially below the first pulley and the second pulley, wherein the movable coupling of the third pulley to the mounting plate allows the third pulley to move in a direction between the upper end and the lower end of the mounting plate, wherein the weight of the third pulley provides tension to the at least one yarn strand to reduce slack from the at least one yarn strand.

[0047] Clause 15. The knitting machine according to Clause 14, wherein the first pulley is coupled to the mounting plate near the upper end of the mounting plate and near the second side of the mounting plate, and wherein the second pulley is coupled to the mounting plate near the upper end of the mounting plate and near the first side of the mounting plate, and wherein at least one strand of yarn is capable of traveling above the first pulley, below the third pulley, and above the second pulley.

[0048] Clause 16. A knitting machine according to any one of Clauses 14 to 15, wherein the mounting plate includes a vertical slot having a bottom end near the lower end of the mounting plate and extending to a top end spaced apart from the bottom end; the tensioning device further includes a rod extending through the vertical slot on the mounting plate, wherein a third pulley is coupled to the rod, and wherein the rod and the third pulley are vertically movable relative to the mounting plate within the vertical slot.

[0049] Clause 17. A knitting machine according to any one of Clauses 14 to 16, wherein the mounting plate has a front and a back, and the tensioning device further includes at least a first bearing coupled to the rod and adjacent to the front and at least a second bearing coupled to the rod and adjacent to the back, wherein at least the first bearing and the second bearing provide controlled movement of the rod within the vertical slot on the mounting plate.

[0050] Clause 18. The knitting machine according to any one of Clauses 14 to 17 further includes a mounting arm connected to the upper end of the mounting plate, the mounting arm facilitating the connection of the tensioning device to a guide rail on the knitting machine.

[0051] Clause 19. A method for providing lateral tension to at least one strand of yarn on a knitting machine, the method comprising: traveling the at least one strand of yarn over a first pulley; traveling the at least one strand of yarn under a weighted third pulley that is vertically movable relative to the first pulley; and traveling the at least one strand of yarn over a second pulley.

[0052] Clause 20. The method according to Clause 19 further includes adding additional weight to the weighted third pulley to increase the lateral tension on the at least one strand.

[0053] Clause 21. The method according to any one of Clauses 19 to 20, wherein the additional weight added to the weighted third pulley is based on at least one of the weight of the at least one strand or the diameter of the at least one strand.

[0054] Clause 22. The method according to any one of Clauses 19 to 21 further includes, after the at least one strand has traveled over the first pulley, traveling the at least one strand around the fourth pulley before traveling the at least one strand under the weighted third pulley.

[0055] Clause 23. The method according to any one of Clauses 19 to 22 further includes adjusting the gap between the first pulley and the fourth pulley to provide additional tension to the at least one strand.

[0056] Clause 24. The method according to any one of Clauses 19 to 23 further includes limiting the distance by which the third pulley can move vertically to adjust the lateral tension added to the strand.

[0057] Clause 25. The method according to any one of Clauses 19 to 24, wherein the amount of lateral tension added to the strand is based on one or more of the weight of the third pulley, the weight of the added additional weight, or the length of vertical movement permitted by the third pulley.

[0058] Clause 26. The method according to any one of Clauses 19 to 24, wherein the amount of lateral tension added to the strand is based on one or more of the groove size of one or more of the first pulley, the second pulley, the third pulley, and the fourth pulley, the range of motion of one or more of the first pulley, the second pulley, the third pulley, and the fourth pulley, the weight of the additional weight, and the number of pulleys that allow the strand to travel thereon.

[0059] Various aspects of this disclosure have been intended to be described in an illustrative rather than restrictive manner. Alternative aspects will become apparent to those skilled in the art without departing from the scope of this disclosure. Those skilled in the art can develop alternative ways to achieve the above improvements without departing from the scope of this disclosure.

[0060] It should be understood that certain features and sub-combinations are useful and can be employed without reference to other features and sub-combinations, and are contemplated within the scope of the claims. Not all steps listed in the various figures need to be performed in the specific order described.

Claims

1. A tensioning device for at least one strand, a portion of the at least one strand extending on a knitting machine between a feeder bar and a source of the strand, the tensioning device comprising: a mounting plate having an upper end and a lower end, a first side and a second side, the second side spaced further from the feeder bar than the first side; a first pulley coupled to the mounting plate; a second pulley coupled to the mounting plate and spaced apart from the first pulley; a third pulley having a first weight, the third pulley movably coupled to the mounting plate between the first pulley and the second pulley and positioned at least partially below the first pulley and the second pulley, wherein the movable coupling of the third pulley to the mounting plate allows the third pulley to move in a direction between the upper end of the mounting plate and the lower end of the mounting plate, wherein the at least one strand is able to travel over the first pulley, below the third pulley, and over the second pulley, wherein the first weight of the third pulley provides a downward force to increase tension on the at least one strand; wherein the mounting plate includes a slot, and wherein the third pulley is coupled to a rod, the rod being movable between a plurality of fixed positions within the slot.

2. The tensioning device of claim 1, wherein the first pulley is coupled to the mounting plate proximate the upper end of the mounting plate and proximate the second side of the mounting plate.

3. The tensioning device of claim 1, wherein the second pulley is coupled to the mounting plate proximate the upper end of the mounting plate and proximate the first side of the mounting plate.

4. The tensioning device of claim 1, wherein the slot has a bottom end at a location proximate the lower end of the mounting plate and extends to a top end spaced apart from the bottom end; the rod having a second weight, wherein the first weight of the third pulley and the second weight of the rod provide a downward force to increase tension on the at least one strand.

5. The tensioning device of claim 4, further comprising a series of stops extending along the slot between the bottom end of the slot and the top end of the slot, the stops being movable between a first position allowing movement of the third pulley along the slot and a second position preventing movement of the third pulley along the slot, wherein in the first position the stops effectively shorten the length of the slot.

6. The tensioning device of claim 4, further comprising a stop positionable along the slot between the bottom end of the slot and the top end of the slot, the stop being movable between a first position allowing movement of the third pulley along the slot and a second position preventing movement of the third pulley along the slot, wherein in the first position the stop effectively shortens the length of the slot.

7. The tensioning device of claim 1, wherein the first pulley and the second pulley are each rotatably coupled to the mounting plate, and wherein the third pulley is rotatably coupled to the rod.

8. The tensioning device of claim 1, wherein the mounting plate has a front face and a back face, the tensioning device further comprising at least a first bearing coupled to the rod and abutting the front face and at least a second bearing coupled to the rod and abutting the back face, wherein at least the first bearing and the second bearing provide controlled movement of the rod within the slot on the mounting plate.

9. The tensioning device of claim 4, wherein the rod is a first rod, and wherein the first rod is removably coupled to the third pulley, the tensioning device further comprising a second rod having a third weight different than the second weight of the first rod and exchangeable with the first rod to allow selective changing of the tension on the at least one strand.

10. The tensioning device of claim 1, further comprising a mounting arm coupled to the upper end of the mounting plate, the mounting arm facilitating coupling of the tensioning device to a rail on the knitting machine.

11. The tensioning device of claim 1, further comprising a fourth pulley coupled to the mounting plate below the first pulley and at a location proximate the second side of the mounting plate, wherein the at least one strand is capable of traveling over the first pulley, around the fourth pulley, under the third pulley, and over the second pulley.

12. The tensioning device of claim 11, wherein any of the first pulley, the second pulley, the third pulley, and the fourth pulley have a groove, and wherein a width of the groove is selectable based on a diameter of the strand.

13. The tensioning device of claim 11, wherein the fourth pulley is adjustably coupled to the mounting plate such that a position of the fourth pulley relative to the mounting plate is adjustable.

14. A knitting machine comprising: a strand source; a feeder rod; at least one strand extending from the strand source and through the feeder rod; and a tensioning device for the at least one strand between the strand source and the feeder rod, the tensioning device comprising: a mounting plate having an upper end, a lower end, a first side, and a second side, the second side spaced further from the feeder rod than the first side; a first pulley coupled to the mounting plate; a second pulley coupled to the mounting plate and spaced apart from the first pulley; and a third pulley rotatably coupled to the rod. -- a third pulley having a weight, the third pulley being movably coupled to the mounting plate between the first pulley and the second pulley and positioned at least partially below the first pulley and the second pulley, wherein the movable coupling of the third pulley to the mounting plate allows the third pulley to move in a direction between the upper end of the mounting plate and the lower end of the mounting plate, wherein the weight of the third pulley provides tension to the at least one strand to reduce slack from the at least one strand; -- wherein the mounting plate includes a slot, and, -- wherein the third pulley is coupled to a rod that is movable between a plurality of fixed positions within the slot.

15. The knitting machine of claim 14, wherein the first pulley is coupled to the mounting plate proximate the upper end of the mounting plate and proximate the second side of the mounting plate, and wherein the second pulley is coupled to the mounting plate proximate the upper end of the mounting plate and proximate the first side of the mounting plate, and wherein the at least one strand is able to travel over the first pulley, under the third pulley, and over the second pulley.

16. The knitting machine of claim 15, wherein the slot has a bottom end at a location proximate the lower end of the mounting plate and extends to a top end spaced apart from the bottom end.

17. The knitting machine of claim 16, wherein the mounting plate has a front face and a back face, the tensioning device further comprising at least a first bearing coupled to the rod and abutting the front face and at least a second bearing coupled to the rod and abutting the back face, wherein at least the first bearing and the second bearing provide controlled movement of the rod within the slot on the mounting plate.

18. The knitting machine of claim 17, further comprising a mounting arm coupled to the upper end of the mounting plate, the mounting arm facilitating coupling of the tensioning device to a rail on the knitting machine.

19. A method for providing lateral tension to at least one strand on a knitting machine having a tensioning device according to any one of claims 1-13, the method comprising: causing the at least one strand to travel over a first pulley; causing the at least one strand to travel under a weighted third pulley that is vertically movable relative to the first pulley; causing the at least one strand to travel over a second pulley.

20. The method of claim 19, further comprising adding an additional weight to the weighted third pulley to increase lateral tension on the at least one strand.

21. The method of claim 20, wherein the additional weight added to the weighted third pulley is based on at least one of a weight of the at least one strand or a diameter of the at least one strand.

22. The method of claim 19, further comprising causing the at least one strand to travel around a fourth pulley after causing the at least one strand to travel over the first pulley and before causing the at least one strand to travel under the weighted third pulley.

23. The method of claim 22, further comprising adjusting a spacing between the first pulley and the fourth pulley to provide additional tension to the at least one strand.

24. The method of claim 19, further comprising limiting a distance the third pulley is able to move vertically to adjust the lateral tension added to the strand.

25. The method of claim 20, wherein an amount of lateral tension added to the strand is based on one or more of a weight of the third pulley, a weight of the additional weight added, or a length of vertical movement allowed by the third pulley.

26. The method of claim 22, further comprising adding an additional weight to the weighted third pulley to increase lateral tension on the at least one strand, wherein an amount of lateral tension added to the strand is based on one or more of a groove size in one or more of the first pulley, the second pulley, the third pulley, and the fourth pulley, a range of motion of one or more of the first pulley, the second pulley, the third pulley, and the fourth pulley, a weight of one or more of the first pulley, the second pulley, the third pulley, and the fourth pulley, a weight of the additional weight, and a number of pulleys over which the strand travels.

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