Double-knitted circular knitted fabric, method of manufacturing same, knitted product, and knitted fabric holding attachment

Abstract

A double-knitted circular knitted fabric includes: a front knitted fabric having a first stitch structure of front yarns; the back knitted fabric is provided with a second stitch structure of back yarns; the front knitted fabric and the back knitted fabric are bound together by utilizing binding yarns in the binding structure. The front knitted fabric has a bottomed hole recessed from a surface of the front knitted fabric and connected to the back knitted fabric, and the front yarn drawn into the back knitted fabric is located on a side of the bottomed hole.

Description

Technical Field

[0001] The present invention relates to a double knitted circular fabric, a knitted product, a method of manufacturing a double knitted circular fabric, and a knitted fabric retaining attachment. Background Art

[0002] A thick double raschel knitted fabric having a mesh structure is used as a covering material for a car seat. The double raschel knitted fabric has a three-dimensional structure in which a front knitted fabric having a mesh structure and a back knitted fabric are hemmed together by a connecting yarn. The double raschel knitted fabric is knitted by a double raschel machine, which is a type of warp knitting machine. The mesh structure knitted by the double raschel machine has holes, and the holes penetrate the front knitted fabric. Therefore, the back knitted fabric can be seen through each through hole of the front knitted fabric.

[0003] A double raschel knitted fabric is shown in Utility Model Registration No. 3080618. In the above double raschel knitted fabric, the back knitted fabric visible from the first grid column of the front knitted fabric and the back knitted fabric visible from the second grid column of the front knitted fabric present different colors from each other. Summary of the invention

[0004] Unfortunately, double Raschel knitted fabrics are expensive. In addition, when debris such as bread crumbs or hair enters the through-holes of the front knitted fabric, the debris may penetrate between the front knitted fabric and the back knitted fabric. This makes it difficult to remove the debris from the double Raschel knitted fabric.

[0005] The above-mentioned problems also apply to covering materials for child seats, covering materials for nursing beds, etc.

[0006] The present invention discloses a new type of knitted fabric that can prevent debris from penetrating from surface holes into the space between the front knitted fabric and the back knitted fabric in an inexpensive manner, a knitted product including the knitted fabric, a method for manufacturing the knitted fabric, and a knitted fabric retaining attachment used in the manufacturing method.

[0007] One aspect of the present invention provides a double knit circular knitted fabric comprising:

[0008] a front knitted fabric having a first stitch structure of a front yarn;

[0009] a back knitted fabric having a second stitch structure of the back yarn; and

[0010] A piping structure, in which the front knitted fabric and the back knitted fabric are piping together using piping yarns, wherein:

[0011] The front knitted fabric has bottomed holes that are recessed from the surface of the front knitted fabric and connected to the back knitted fabric, and

[0012] The front yarn drawn into the back knitted fabric is located on the side of the bottomed hole.

[0013] Another aspect of the present invention provides a knitted product comprising the double-knitted circular fabric.

[0014] Another aspect of the present invention provides a method for manufacturing a double-sided circular knitted fabric using a double-sided circular knitting machine, the double-sided circular knitting machine comprising: a needle cylinder having cylinder needles arranged thereon, a needle dial having dial needles arranged thereon, a needle selector, and a support body located outside the needle cylinder, the method comprising:

[0015] A holding step of holding the knitted fabric using a spring steel wire to prevent the knitting yarn from being tangled at a holding position between the cylinder needle and the dial needle, the spring steel wire leading from an attachment base attached to the support body to the holding position; and

[0016] Control step: Control the operation of the cylinder needle and the dial needle and the supply of the knitting yarn so as to knit the double-sided knitted circular fabric, the knitting yarn includes a front yarn, a back yarn and a piping yarn, the double-sided knitted circular fabric includes: a front knitted fabric having a first stitch structure of the front yarn, a back knitted fabric having a second stitch structure of the back yarn, and a piping structure, in which the front knitted fabric and the back knitted fabric are piping together using the piping yarn, the front knitted fabric has a bottomed hole recessed from the surface of the front knitted fabric and connected to the back knitted fabric, the front yarn is pulled into the back knitted fabric, and the front yarn is located on the side of the bottomed hole.

[0017] Another aspect of the present invention provides a knitted fabric holding attachment for attachment to a double-sided knitted circular knitting machine, the double-sided knitted circular knitting machine comprising: a needle cylinder on which a cylinder needle is arranged, a needle dial on which a dial needle is arranged, a needle selector, and a support body located outside the needle cylinder, the knitted fabric holding attachment holding a knitted fabric to prevent the knitted yarn from being tangled at a holding position between the cylinder needle and the dial needle, the knitted fabric holding attachment comprising:

[0018] an attachment base for attachment to the support; and

[0019] A spring steel wire leads from the attachment base to the holding location to hold the knitted fabric at the holding location.

[0020] These and other features, aspects, and advantages of the present invention will become apparent to those skilled in the art from the following detailed description of preferred non-limiting exemplary embodiments together with the accompanying drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a schematic perspective view showing an example of a double-knit circular fabric.

[0022] Figure 2 is a schematic diagram showing an example of a knitting structure of a double-knit circular fabric.

[0023] Figure 3 is a schematic organization diagram showing an example of knitting of a double knit circular fabric.

[0024] Figure 4 is a schematic diagram showing an example of the essential parts of a double jersey circular knitting machine to which a knitted fabric retaining attachment is attached.

[0025] Figure 5 is a schematic perspective view showing an example of a knitted fabric retaining attachment.

[0026] Figure 6 : is a schematic plan view showing an example of the positional relationship between a needle and a knitted fabric holding attachment.

[0027] Figure 7 is a photograph showing a sample of a double knit circular knit fabric.

[0028] Figure 8 It is a schematic diagram illustrating the prevention of debris from penetrating from the surface holes into the space between the front knitted fabric and the back knitted fabric.

[0029] Fig. 9 : is a schematic diagram showing the knitting structure of a double raschel knitted fabric according to a comparative example.

[0030] Fig.10 is a schematic diagram showing a knitted fabric retaining attachment including a rigid metal plate having a wear area according to a comparative example.

[0031] Fig.11 is a photograph showing a sample of a double-knit circular knit fabric according to a comparative example. DETAILED DESCRIPTION

[0032] Some embodiments of the present invention will be described below. Of course, the following embodiments are only illustrative examples of the present invention, and all features shown in the embodiments may not necessarily be essential to the solution.

[0033] (1) Overview of the Invention

[0034] First, refer to Figures 1 to 11 The examples shown in the figure give an overview of the present disclosure. The figures in this application are schematic examples, the magnification of each direction shown in these figures may be different, and these figures may not be consistent. Of course, each element of the present disclosure is not limited to the specific examples indicated by the figure numerals.

[0035] In the present application, the numerical range "Min to Max" means above the minimum value Min and below the maximum value Max.

[0036] (Example 1)

[0037] like Figure 1 , Figure 2 As illustrated in Figures 1 and 2, an embodiment of the present disclosure provides a double-sided circular knitted fabric 1, which includes: a front knitted fabric 10 having a first stitch structure 12 with a front yarn 11, a back knitted fabric 20 having a second stitch structure 22 with a back yarn 21, and a piping structure 30 in which the front knitted fabric 10 and the back knitted fabric 20 are piping together using a piping yarn 31. The front knitted fabric 10 has a bottomed hole 40 that is recessed from the surface 13 of the front knitted fabric and connected to the back knitted fabric 20, and the front yarn 11 drawn into the back knitted fabric 20 is located on the side 43 of the bottomed hole 40.

[0038] Since the front knitted fabric 10 and the back knitted fabric 20 are hemmed together using the hemming yarn 31, the double-sided circular knitted fabric 1 is thicker and can be used as a corrugated knitted fabric (carton knitted fabric) or the like. The front knitted fabric 10 has a bottomed hole 40 having a stitch structure 12 formed with the front yarn 11 as a weft yarn, the bottomed hole 40 is recessed from the surface 13 and connected to the back knitted fabric 20, and the front yarn 11 drawn into the back knitted fabric 20 is located on the side 43 of the bottomed hole 40. Figure 8 As illustrated, even if debris such as bread crumbs 301 or hair 302 enters the bottomed hole 40, the debris is prevented from penetrating between the front knitted fabric 10 and the back knitted fabric 20.

[0039] Fig. 9The knitting structure of a double raschel knitted fabric 801 according to a comparative example is schematically shown. The double raschel knitted fabric 801 includes: a front knitted fabric made of a front yarn 11 as a warp yarn, a back knitted fabric made of a back yarn 21 as a warp yarn, and a piping structure. The front knitted fabric is knitted so that a through hole will be formed on the front knitted fabric formed by the front yarn 11 swinging in the weft direction. The back knitted fabric is knitted by the back yarn 21 swinging in the weft direction. In the piping structure, the front knitted fabric and the back knitted fabric are piped together by the piping yarn 31. Due to the structure of the double raschel machine, the front yarn 11 cannot bypass the back. This makes the piping yarn 31 present on the side of the hole 840 visible on the front knitted fabric. For this reason, if debris such as bread crumbs 301 or hair 302 enters the hole 840, the debris (301 and 302) will penetrate between the front knitted fabric and the back knitted fabric. This makes it difficult to remove these debris ( 301 and 302 ) from the double raschel knit 801 .

[0040] exist Figure 8 In the illustrated double-sided circular knitted fabric 1, the front yarn 11 drawn into the back knitted fabric 20 is located on the side 43 of the bottomed hole 40. This prevents debris from penetrating from the bottomed hole 40 into the space between the front knitted fabric 10 and the back knitted fabric 20. Therefore, the above-mentioned embodiment 1 can provide a novel double-sided circular knitted fabric that can prevent debris from penetrating from the surface hole into the space between the front knitted fabric and the back knitted fabric in an inexpensive manner.

[0041] In this document, "bottomed hole" refers to a hole with a bottom. The front yarn is pulled into the back knitted fabric at the bottom of the bottomed hole of the front knitted fabric. The bottomed hole has a size of at least one course in the warp direction.

[0042] The additional remarks mentioned above apply to the following embodiments.

[0043] (Example 2)

[0044] The front knitted fabric 10 may have a plurality of bottomed holes 40. The surface 13 of the front knitted fabric 10 may have a pattern 14 of the bottomed holes 40. The present embodiment may provide a novel double-sided circular knitted fabric having a pattern formed by bottomed holes on the surface.

[0045] (Example 3)

[0046] The bottomed hole 40 may include a bottomed groove 44 having a longitudinal direction oriented in the warp direction D2. This embodiment may provide a double-sided circular knitted fabric having bottomed grooves on the surface thereof having a longitudinal direction oriented in the warp direction.

[0047] (Example 4)

[0048] Another embodiment of the present disclosure provides a knitted product including a double knitted circular fabric 1. The present embodiment can provide a knitted product including a novel double knitted circular fabric capable of preventing debris from penetrating from surface holes into a space between a front knitted fabric and a back knitted fabric in an inexpensive manner.

[0049] Herein, examples of knitted products include: products formed by cutting a double-sided knitted circular fabric, products formed by processing the edges of the cut double-sided knitted circular fabric by sewing, etc., products formed by sewing the cut double-sided knitted circular fabric together, etc. The knitted product may include at least one accessory that is different from the double-sided knitted circular fabric. Examples of knitted products include covering materials for vehicle seats, covering materials for child seats, covering materials for nursing beds, etc.

[0050] The double-sided circular knitted fabric 1 can be produced by a double-sided circular knitting machine 200, which includes: a needle cylinder 210 on which a cylinder needle 211 is arranged; a needle dial 220 on which a dial needle 221 is arranged; a needle selector 230; and a support body 240 located outside the needle cylinder 210, such as Figure 4 As illustrated. In the case where the double-sided circular knitted fabric 1 is thick like a corrugated knitted fabric, it is necessary to raise the position of the needle dial 220 to widen the gap between the needle cylinder 210 and the needle dial 220. As the position of the needle dial 220 is raised, the knitted fabric 50 connected to the knitting yarn 51 is lifted, and thus there is a possibility that the knitting yarn 51 is tangled without the knitted fabric holding attachment. It is therefore conceivable that a knitted fabric holding attachment is attached to the support body 240, and the knitted fabric holding attachment holds the knitted fabric 50 to prevent the knitted yarn 51 from being tangled at the holding position P1 between the cylinder needle 211 and the dial needle 221.

[0051] In order to knit a double-sided circular knitted fabric having a pattern such as bottomed holes 40, a knitted fabric holding attachment is attached to the support body 240, the knitted fabric holding attachment including an attachment base attached to the support body 240 and a rigid metal plate leading from the attachment base to the holding position P1. In this case, a defect is formed on the double-sided circular knitted fabric.

[0052] Fig.10 A knitted fabric holding attachment 900 according to a comparative example is schematically shown. The knitted fabric holding attachment 900 includes a rigid metal plate 920 that holds the knitted fabric between the cylinder needle and the dial needle to prevent the knitted yarn from being tangled. Fig.10As shown in the double-dotted line encircled circle in FIG, the cross section of the rigid metal plate 920 is approximately rectangular. When inspecting the knitted fabric retaining attachment 900, a wear area 930 formed by the cylinder needle hitting the rigid metal plate 920 is identified on the vertical surface of the rigid metal plate 920, which faces the cylinder needle.

[0053] Fig.11 A photograph of a sample of a double jersey circular knitted fabric according to a comparative example is schematically shown.

[0054] When verifying the operation of the double jersey circular knitting machine, it was found that due to the capture of the knitting yarn on the wear area 930 on the rigid metal plate 920, the double jersey circular knitted fabric was formed with abrasions such as Fig.11 Defects such as broken yarn are shown.

[0055] Therefore, it is desirable to prevent defects from forming on a double jersey circular knit fabric due to catching of knit yarn on wear areas on the knit retaining attachment.

[0056] (Example 5)

[0057] like Figure 3 and Figure 4 As illustrated, another embodiment of the present disclosure provides a method for manufacturing a double-sided circular knitted fabric 1 using a double-sided circular knitting machine 200, the double-sided circular knitting machine 200 comprising: a needle cylinder 210 on which a cylinder needle 211 is arranged; a needle dial 220 on which a dial needle 221 is arranged; a needle selector 230; and a support body 240 located outside the needle cylinder 210. The method comprises the following steps:

[0058] (a1) Holding Step ST1 : The knitted fabric 50 is held by a spring wire (wire for spring) 120 leading from an attachment base 110 attached to the support body 240 to the holding position P1 to prevent the knitting yarn 51 from being tangled at the holding position P1 between the cylinder needle 211 and the dial needle 221 .

[0059] (a2) Control step ST2: Control the operation of the cylinder needle 211 and the dial needle 221 and the supply of the knitting yarn 51 so as to knit the double-sided knitted circular fabric 1, the knitting yarn 51 including the front yarn 11, the back yarn 21 and the piping yarn 31, the double-sided knitted circular fabric 1 including: a front fabric 10 having a first stitch structure 12 of the front yarn 11, a back fabric 20 having a second stitch structure 22 of the back yarn 21, and a piping structure 30 in which the front fabric 10 and the back fabric 20 are piping together by the piping yarn 31, the front fabric 10 having a bottomed hole 40 recessed from the surface 13 of the front fabric 10 and connected to the back fabric 20, the front yarn 11 being pulled into the back fabric 20, and the front yarn 11 being located on the side 43 of the bottomed hole 40.

[0060] When the needle hits the spring steel wire 120, the spring steel wire 120 bends due to its elasticity. This prevents a specific area of ​​the spring steel wire 120 from being worn. Therefore, a double-sided knitted circular knitted fabric 1 in which defects are prevented, which are formed by catching the knitting yarn 51 on the worn area on the knitted fabric holding attachment, can be produced. In the obtained double-sided knitted circular knitted fabric 1, the front yarn 11 is located on the side 43 of the bottomed hole 40 that is recessed from the surface 13 and connected to the back knitted fabric 20. This prevents debris from penetrating from the bottomed hole 40 into the space between the front knitted fabric 10 and the back knitted fabric 20. Therefore, the above-mentioned embodiment can provide a method for manufacturing a double-sided knitted circular knitted fabric that can prevent debris from penetrating from the surface hole into the space between the front knitted fabric and the back knitted fabric in an inexpensive manner.

[0061] Herein, examples of spring wire include piano wire, stainless steel wire for springs, hard drawn wire suitable for springs (eg, oil tempered wire for mechanical springs), etc. This additional description applies to the following embodiments.

[0062] (Example 6)

[0063] The spring wire 120 may be elliptical or oval in cross section with a maximum diameter of 0.7 mm to 1.2 mm, including a circular cross section with a diameter of 0.7 mm to 1.2 mm.

[0064] In this case, the spring wire 120 hit by the cylinder needle 211 escapes laterally from the cylinder needle 211, and the spring wire 120 is elliptical or oval (including circular) in cross section. This further prevents abrasion of a specific area of ​​the spring wire 120. According to the above embodiment, defects on the double-sided circular knitted fabric, which are formed due to the capture of knitted yarns in the abrasion area on the knitted fabric holding attachment, can be further prevented.

[0065] (Example 7)

[0066] The knitted fabric holding attachment 100 including the attachment base 110 and the spring steel wire 120 prevents the above-mentioned defects on the double-sided knitted circular knitted fabric 1, and realizes the double-sided knitted circular knitted fabric 1 that can prevent debris from penetrating from the holes of the surface 13 into the space between the front knitted fabric 10 and the back knitted fabric 20 in an inexpensive manner. Another embodiment of the present disclosure provides a knitted fabric holding attachment 100 to be attached to a double-sided knitted circular knitting machine 200. The knitted fabric holding attachment 100 holds the knitted fabric 50 to prevent the knitting yarn 51 from being tangled at the holding position P1 between the cylinder needle 211 and the dial needle 221. The knitted fabric holding attachment 100 includes the attachment base 110 to be attached to the support body 240 and the spring steel wire 120 leading from the attachment base 100 to the holding position P1 to hold the knitted fabric 50 at the holding position P1.

[0067] When the needle hits the spring wire 120, the spring wire 120 bends due to its elasticity. This prevents a specific area of ​​the spring wire 120 from being worn. Therefore, the above-mentioned embodiment can provide a knitted fabric retaining attachment that can prevent defects on double-knitted circular knitted fabrics, which are formed by catching the knitting yarn on the worn area on the knitted fabric retaining attachment.

[0068] As described above, the spring wire 120 may be elliptical or oval in cross section with a maximum diameter of 0.7 mm to 1.2 mm, including a circular cross section with a diameter of 0.7 mm to 1.2 mm.

[0069] (2) Specific examples of double-knit circular fabrics

[0070] Figure 1 A specific example of a double-knit circular knitted fabric 1 used for a covering material for a vehicle seat is schematically illustrated. Figure 2 The knitting structure of a double-sided circular knitted fabric 1 as a specific example is schematically illustrated. It should be noted that the various figures disclosed in this application are merely schematic diagrams for explaining the purpose of a specific example in an easy-to-understand manner. For example, Figure 1 The thickness of the double-sided circular knitted fabric 1 in is exaggerated, and Figure 2 The pin structures 12 and 22 shown in FIG. 1 are simplified.

[0071] Figure 1 and Figure 2The double-sided knitted circular fabric 1 shown is a thick corrugated fabric including a front knitted fabric 10, a back knitted fabric 20 and a piping structure 30. The double-sided knitted circular fabric 1 according to this specific example is a novel corrugated fabric having bottomed holes 40 recessed from the surface 13 of the front knitted fabric 10. The double-sided knitted circular fabric 1 is knitted by a double-sided knitted circular knitting machine 200, to which a novel knitted fabric retaining attachment 100 is attached, as shown in FIG. Figures 4 to 6 exemplified. Figure 1 The surface 13 is shown with a mesh pattern as the pattern 14 of bottomed holes 40 .

[0072] The double-sided circular knitted fabric 1 has a knitted structure along the weft direction D1, such as Figure 2 As shown. Figure 2 When the knitting structure shown is repeated in the warp direction D2 crossing the weft direction D1 , bottomed grooves 44 having a longitudinal direction oriented in the warp direction D2 are formed as bottomed holes 40 .

[0073] The front knitted fabric 10 has a stitch structure 12 of a front yarn 11 as a weft yarn. The back knitted fabric 20 has a stitch structure 22 of a back yarn 21 as a weft yarn. The piping structure 30 is a pleat structure for piping the front knitted fabric 10 and the back knitted fabric 20 together with the piping yarn 31 as the weft yarn. The front knitted fabric 10 has a bottomed hole 40 that is recessed from the surface 13 of the front knitted fabric 10 and connected to the back knitted fabric 20. At the position of the bottomed hole 40, the front yarn 11 is caught and pulled into the stitch structure 22 of the back yarn 21. As a result, each bottomed hole 40 has an opening 41 on the surface 13. The front yarn 11 has a portion caught in the back knitted fabric 20 that is located at the bottom 42 of the bottomed hole 40. The front yarn 11 pulled into the back knitted fabric 20 is located on the side 43 of the bottomed hole 40. As shown in FIG. Figure 8 As shown, even if the debris ( 301 and 302 ) enters the bottomed hole 40 , the front yarn 11 drawn into the back knitted fabric 20 can prevent the debris ( 301 , 302 ) from penetrating between the front knitted fabric 10 and the back knitted fabric 10 .

[0074] There is no particular restriction on the types of the front yarn 11, the back yarn 21 and the piping yarn 31. Examples of the front yarn 11, the back yarn 21 and the piping yarn 31 include filament yarns of synthetic fibers, spinning of synthetic fibers, spinning of natural fibers, blended yarns, twisted yarns, combined filament yarns, etc. Examples of synthetic fibers include polyester fibers, polyamide fibers, acrylic fibers, polyolefin fibers, etc. Examples of natural fibers include wool, cotton, hemp, etc. Dyed yarns can also be used for these yarns. There is no particular restriction on the thickness of the front yarn 11, the back yarn 21 and the piping yarn 31. Of course, different types of yarns can be used for the front yarn 11, the back yarn 21 and the piping yarn 31.

[0075] Examples of the stitch structures 12 and 22 include various structures such as a plain knit (jersey) structure, a rib knit structure, a pearl knit structure, and the like.

[0076] The depth of the bottomed hole 40 may be, for example, 1.0 mm to 4.0 mm. To increase the depth of the bottomed hole 40, the needle dial 220 is raised (see Figure 4 ) is sufficient to thicken the double-sided knitted circular fabric 1. In order to reduce the depth of the bottomed hole 40, it is sufficient to lower the needle dial 220 to thin the double-sided knitted circular fabric 1.

[0077] (3) Specific example of method for producing double-knit circular knitted fabric

[0078] Figure 3 A knitting structure diagram of a double-knit circular knitted fabric 1 is schematically illustrated. Figure 3 The upper part of shows the needle arrangement of the feeders F1 to F4 in the portion where the bottom hole 40 is formed in the stitch row. Figure 3 The lower part of FIG. 1 shows the needle arrangement of the feeders F1 to F4 in the portion where the bottom hole 40 is not formed in the stitch row. In each needle arrangement, the arrangement of the cylinder needle 211 is shown below, and the arrangement of the dial needle 221 is shown above. Figure 3 The organizational diagram shown executes the control step ST2.

[0079] Feeder F1 supplies the piping yarn 31 for the pleat structure to a part of the needles (211 and 221). Feeder F2 after feeder F1 supplies the piping yarn 31 for the pleat structure to the needles (211 and 221) at a position different from the yarn supply position of feeder F1. Feeder F3 after feeder F2 supplies the front yarn 11 to the dial needle 221. The dial needle 221 knits the stitch structure 12 of the front yarn 11 by a knitting operation. The structure corresponding to feeder F3 includes a pleat structure. Feeder F4 after feeder F3 supplies the back yarn 21 to the cylinder needle 211. The cylinder needle 211 knits the stitch structure 22 of the back yarn 21 by a knitting operation. The front yarn 11 supplied from feeder F3 is pulled into the stitch structure 22 of the back yarn 21 at the position of the bottom hole 40.

[0080] As a result, a tubular double-sided circular knitted fabric 1 is knitted in which the front knitted fabric 10 and the back knitted fabric 20 are hemmed together with the hemming yarn 31. In the double-sided circular knitted fabric 1, the front knitted fabric 10 having the bottomed holes 40 is located inside the back knitted fabric 20.

[0081] In the case of forming a bottomed hole 40 of one row of stitches in the warp direction D2, the following steps are performed in order: Figure 3 The knitting with "no bottom hole" shown in the lower part of Figure 3 The knitting of "with bottom holes" of one row of stitches shown in the upper part of Figure 3 The knitting of "no bottom hole" shown in the lower part of FIG. In the case where the bottom groove 44 is formed, the knitting of the plurality of coil rows is repeated. Figure 3 In the case where N rows of bottomed holes 40 are formed in the warp direction D2, knitting of "no bottomed holes", knitting of N rows of "with bottomed holes", and knitting of "no bottomed holes" are performed in sequence. Herein, N is an integer of 2 or more.

[0082] Figure 4 Essential parts of a double jersey circular knitting machine 200 for knitting a double jersey circular knitted fabric 1 are schematically illustrated.

[0083] The double-sided circular knitting machine 200 includes: a needle cylinder 210 on which a cylinder needle 211 is arranged, a needle dial 220 on which a dial needle 221 is arranged, a needle selector 230, and a support body 240 located outside the needle cylinder 210. Each cylinder needle 211 is a latch needle, in which a hook 212 located at the tip is opened and closed by a latch 213, and is arranged so that the cylinder needle 211 can be vertically advanced and retracted relative to the needle cylinder 210. Each dial needle 221 is a latch needle, in which a hook 222 located at the tip is opened and closed by a latch 223, and is arranged so that the dial needle 221 can be horizontally advanced and retracted relative to the needle dial 220. Figure 3 In the example shown, the knitting yarn 51 caught by the cylinder needle 211 is the front yarn 11 or the piping yarn 31, and the knitting yarn 51 caught by the dial needle 221 is the back yarn 21 or the piping yarn 31. The needle dial 220 is supported on a support portion (not shown) of the double-sided knitting circular knitting machine 200 so that the height of the needle dial 200 can be changed. The needle selector 230 controls the operation of the cylinder needle 211 individually. The needle selector 230 can control the operation of the dial needle 221 individually. The double-sided knitting circular knitting machine 200 includes a control unit. The control unit includes, for example, a CPU (central processing unit), a ROM (read-only memory), and a RAM (random access memory). The needle selector 230 controls the operation of the needle individually according to a signal from the control unit.

[0084] In the case where the double-sided circular knitted fabric 1 is thick, it is necessary to raise the position of the needle dial 220 to widen the gap between the needle cylinder 210 and the needle dial 220. As the position of the needle dial 220 is raised, the knitted fabric 50 connected to the knitting yarn 51 is lifted, and thus the chance of the knitting yarn 51 being tangled becomes higher. Therefore, the knitted fabric holding attachment 100 is attached to the upper surface 241 of the support body 240, and the knitted fabric holding attachment 100 holds the knitted fabric 50 to prevent the knitting yarn 51 from being tangled at the holding position P1 between the cylinder needle 211 and the dial needle 221.

[0085] In accordance with Fig.10 In the case where the knitted fabric retaining attachment 900 of the comparative example shown is attached to the support body 240 to knit a double-sided knitted circular knitted fabric having a pattern such as bottomed holes 40, a pattern such as Fig.11 Defects shown. Fig.10 The knitted fabric retaining attachment 900 shown includes a rigid metal plate 920 that is attached to the Figure 4The attachment base of the upper surface 241 is shown leading to the holding position P1. A wear area 930 is identified on the vertical surface of the rigid metal plate 920, where the cylinder needle hits the rigid metal plate 920, the vertical surface facing the cylinder needle. When verifying the operation of the double-sided circular knitting machine 200, it was found that due to the capture of the knitting yarn 51 on the wear area 930 on the rigid metal plate 920, a wear area 930 is formed on the double-sided circular knitted fabric. Fig.11 Defects shown.

[0086] The knitting yarn 51 is fed from the feeder to the needles (211 and 221) at a constant speed by the yarn feeding device. If the double-knit circular knitted fabric is a normal corrugated knitted fabric without a pattern such as the bottomed hole 40, the cylinder needle 211 plus the dial needle 221 will operate regularly. For this reason, the operation of the knitting yarn 51 pulling the cylinder needle 211 toward the inside of the needle cylinder 210 does not occur. As a result, the cylinder needle 211 coming out of the needle cylinder 210 does not hit the rigid metal plate 920.

[0087] In the case of a double-knit circular knitted fabric having a pattern such as the bottomed hole 40, the extent to which the cylinder needle 211 protrudes from the needle cylinder 210 becomes irregular. This sometimes causes the knitting yarn 51 to pull the cylinder needle 211 toward the inside of the needle cylinder 210. For example, in the case where the extent to which the cylinder needle 211 protrudes from the needle cylinder 210 is small, the knitting yarn 51 becomes loose, and in the case where the extent to which the cylinder needle 211 protrudes from the needle cylinder 210 is large, the knitting yarn 51 pulls the cylinder needle 211 toward the inside of the needle cylinder 210. The cylinder needle 211 moving toward the inside hits the rigid metal plate 920, and thereby forms a wear area 930 on the rigid metal plate 920.

[0088] For the above reasons, a double jersey circular knitted fabric having a pattern such as bottomed holes 40 has not been produced in a double jersey circular knitting machine equipped with the knitted fabric holding attachment 900. In addition, a double raschel knitted fabric having a mesh structure is expensive.

[0089] In this particular example, the knitted fabric retaining attachment 100 including the spring wire 120 that retains the knitted fabric 50 in the retaining position P1 is attached to the double-sided circular knitting machine 200. As a result, by performing Figure 4 The holding step ST1 and Figure 3 The control step ST2 shown can obtain a novel double-sided circular knitted fabric 1 having a flawless pattern.

[0090] Figure 5 A knitted fabric retaining attachment 100 to be attached to a double jersey circular knitting machine 200 is schematically illustrated. Figure 6 The positional relationship between the needles ( 211 and 221 ) and the knitted fabric retaining attachment 100 is schematically illustrated.

[0091] The knitted fabric retaining attachment 100 includes an attachment base 110 and a spring steel wire 120. The attachment base 110 includes a horizontal planar portion 111 having a vertically oriented hole 112, a vertical shaft portion 113 having a horizontally oriented through hole 114, and a wire support portion 115. Figure 5 114, the hole 112 is hidden by the vertical shaft portion 113. The spring steel wire 120 includes: a base portion 121 to be supported by the wire support portion 115, a fabric holding portion 123 to be positioned at the holding position P1, and a bent portion 122 oriented from the base portion 121 and connected to the fabric holding portion 123, the longitudinal direction of the fabric holding portion 123 being different from the longitudinal direction of the base portion 121. The wire support portion 115 supports the base portion 121 so that the fabric holding portion 123 can hold the knitted fabric 50 at the holding position P1, and the fabric holding portion 123 is fixed to the vertical shaft portion 113 by a screw SC3 with the support portion 115 passing through the through hole 114. The vertical shaft portion 113 is fixed to the horizontal plane portion 111 by a screw SC2, and the lower portion of the vertical shaft portion 113 is in the hole 112. The horizontal plane portion 111 is fixed to the upper surface 241 of the support body 240 by the screw SC1, so that the fabric holding portion 123 can hold the knitted fabric 50 at the holding position P1. In this way, the attachment base 110 is attached to the support body 240, and the spring wire 120 leading from the attachment base 100 to the holding position P1 holds the knitted fabric 50 at the holding position P1.

[0092] For the spring steel wire 120, a steel wire with elasticity can be used. Examples of the spring steel wire 120 include piano steel wire, stainless steel wire for springs, and hard-drawn steel wire suitable for springs, etc. The piano steel wire is typically made of high-quality piano steel wire material with a carbon content of 0.60% to 0.95%, and has a stable elasticity suitable for high-grade springs. Therefore, the piano steel wire is a preferred material for the spring steel wire 120. Since the spring steel wire 120 has the elasticity as a spring, the spring steel wire 120 hit by the cylinder needle 211 is bent due to the elasticity. This prevents the spring steel wire 120 from being worn. As a result, a patterned double-sided knitted circular knitted fabric 1 in which defects are prevented can be obtained, which are formed by catching the knitting yarn 51 on the wear area on the knitted fabric retaining attachment.

[0093] The cross section of the spring wire 120 is preferably elliptical or oval (including circular). Fig.10In the case of a substantially rectangular shape like the comparative example shown, since the cylinder needle 211 that irregularly protrudes from the syringe 210 hits the corner of the rigid metal plate 920, the wear area 930 is easily formed at the corner of the rigid metal plate 920. Since the spring steel wire 120 with an elliptical or oval (including circular) cross section has no corners, the spring steel wire 120 is unlikely to be worn even if the cylinder needle 211 hits the spring steel wire 120. In the case of the spring steel wire 120 with an elliptical or oval (including circular) cross section, the spring steel wire 120 escapes laterally from the cylinder needle 211. This prevents a specific area of ​​the spring steel wire 120 from being worn.

[0094] In order to hold the knitted fabric 50 at the holding position P1 and prevent the knitting yarn 51 from being tangled, it is preferred that the diameter d1 of the spring steel wire 120 having a circular cross section is greater than or equal to 0.7 mm. In the case where the cross section of the spring steel wire 120 is elliptical or oval, it is preferred that the maximum diameter of the cross section of the spring steel wire 120 is greater than or equal to 0.7 mm. In addition, in order to allow the elastic steel wire 120 that hits the cylinder needle 211 to easily escape to the cylinder needle 211 side, it is preferred that the diameter d1 of the spring steel wire 120 having a circular cross section is less than or equal to 1.2 mm. In the case where the cross section of the spring steel wire 120 is elliptical or oval, it is preferred that the maximum diameter of the cross section of the spring steel wire 120 is less than or equal to 1.2 mm. The diameter d1 or the maximum diameter of the cross section of the spring steel wire 120 should be adjusted according to the specification of the double-sided circular knitting machine 200 or the thickness of the knitting yarn 51.

[0095] like Figure 4 As shown, it is preferred that the holding position P1 is a position where the fabric holding portion 123 (spring wire 120) is located in at least a portion of the area A1. In the double-knit circular knitting machine 200, the area A1 is located inside the line connecting the position P2 where the cylinder needle 211 extends out of the needle cylinder 210 and the position P3 where the dial needle 221 extends out of the needle dial 220.

[0096] like Figure 6 As shown, the fabric holding portion 123 covers the needle advancing and retracting range A2, within which the needles (211 and 221) advance and retract in accordance with the yarn supplied from the feeder. Preferably, the length L1 of the fabric holding portion 123 (see Figure 5 ) exceeds the needle advancement and retraction range A2. In the case where the length of the needle advancement and retraction range A2 is 1 inch, the length L1 of the fabric holding portion 123 may be, for example, 26 mm to 40 mm, preferably 27 mm to 35 mm, and more preferably 28 mm to 30 mm.

[0097] The above-mentioned knitted fabric holding attachment 100 is attached to the support body 240 so that the fabric holding portion 123 can be positioned at the holding position P1 within the needle advancement and retraction range A2 corresponding to the feeder performing the knitting operation. Figure 3 As shown in the organizational diagram in , the knitted fabric holding attachment 100 is attached to the support body 240 so that the fabric holding portion 123 can be positioned at the holding position P1 within the needle advancement and retraction range A2 corresponding to the feeders F3 and F4 that respectively perform knitting operations.

[0098] A double-sided circular knitted fabric 1 having a pattern such as bottomed holes 40 is produced by the double-sided circular knitting machine 200 by performing a holding step ST1 and a control step ST2. In the holding step ST1, the spring wire 120 holds the knitted fabric 50 to prevent the knitting yarn 51 from being tangled at the holding position P1. In the control step ST2, the double-sided circular knitting machine 200 (particularly, the control unit and the needle selector 230) controls the operation of the needles (cylinder needles 211 and dial needles 221) and the supply of the knitting yarn 51 so as to knit the double-sided circular knitted fabric 1 having the bottomed holes 40. As a result, a novel double-sided circular knitted fabric 1 is knitted in which the front yarn 11 is located on the side 43 of the bottomed hole 40 that is recessed from the surface 13 and connected to the back knitted fabric 20.

[0099] When the cylinder needle 211 pulled by the knitting yarn 51 hits the spring steel wire 120, the spring steel wire 120 bends due to its elasticity. This prevents a specific area of ​​the spring steel wire 120 from being worn. Therefore, a new double-sided knitted circular knitted fabric 1 in which defects due to the capture of the knitting yarn 51 on the worn area on the knitted fabric holding attachment are prevented can be produced. In the obtained double-sided knitted circular knitted fabric 1, as shown in FIG. Figure 1 and Figure 2 As shown, the front yarn 11 is located on the side 43 of the bottomed hole 40.

[0100] Figure 7 Shown according to Figure 3 The structure diagram shown is a photograph of a sample obtained by actually knitting a double-sided circular fabric having bottom holes 40. Figure 7 The bottomed holes 40 of the illustrated double-sided circular knitted fabric sample include bottomed holes 40a in one row of stitches along the warp direction D2, bottomed slots 44a in two rows of stitches along the warp direction D2, and bottomed slots 44b in six rows of stitches along the warp direction D2. Figure 7 A mesh pattern is shown formed as a pattern of bottomed holes on the surface of a double-knit circular knitted fabric sample. Figure 7 No hygroscopicity was observed in the double jersey circular knit fabric samples shown. Fig.11Therefore, by attaching the knitted fabric retaining attachment 100 including the spring steel wire 120 to the double jersey circular knitting machine 200, it has been confirmed that a novel double jersey circular knitted fabric 1 having a flawless pattern can be produced.

[0101] In accordance with Fig. 9 In the double raschel knitted fabric 801 of the comparative example shown, the front yarn 11 is not pulled into the back knitted fabric due to the structure of the double raschel machine. In this case, if the scraps (301 and 302) enter the holes 840 visible on the front knitted fabric, the scraps (301 and 302) penetrate between the front knitted fabric and the back knitted fabric. As a result, it is sometimes impossible to remove these scraps (301 and 302) from the double raschel knitted fabric 801.

[0102] exist Figure 8 In the double-sided circular knitted fabric 1 shown, the front yarn 11 is located on the side 43 of the bottomed hole 40. This prevents debris (301 and 302) from penetrating from the bottomed hole 40 into the space between the front knitted fabric 10 and the back knitted fabric 20. Therefore, the double-sided circular knitted fabric 1 is a novel knitted fabric that can prevent debris from penetrating from the surface holes into the space between the front knitted fabric and the back knitted fabric in an inexpensive manner.

[0103] according to Figure 3 The organization diagram shown can easily knit a double-sided circular knitted fabric 1 having bottom grooves 44 in the longitudinal direction oriented in the warp direction D2. Therefore, this embodiment can easily provide a novel double-sided circular knitted fabric having bottom grooves on the surface, the bottom grooves having the longitudinal direction oriented in the warp direction.

[0104] (4) Specific examples of knitted products

[0105] Examples of knitted products include covering materials for car seats, covering materials for child seats, covering materials for nursing beds, etc., and the knitted products include a double-sided knitted circular fabric 1. The knitted product as a covering material for a seat can be produced by, for example, cutting the double-sided knitted circular fabric 1 to fit the shape of the seat, and processing the edges of the cut double-sided knitted circular fabric by sewing, etc. The knitted product such as the covering material for a seat can be produced by sewing the cut double-sided knitted circular fabrics together. The knitted product can be produced by sewing at least one accessory to the cut double-sided knitted circular fabric.

[0106] (5) Modifications

[0107] Various modifications of the present invention are available.

[0108] For example, in the case where the needle selector 230 individually controls the operation of the dial needle 221 , a tubular double-sided circular knitted fabric 1 in which the front knitted fabric 10 having the bottomed hole 40 is outside the back knitted fabric 20 can be knitted.

[0109] In the case where the needle selector 230 controls the operation of the cylinder needle 211 and the dial needle 221 individually, a double-sided knitted circular fabric having a bottomed groove having a longitudinal direction oriented in the weft direction D1 can be knitted. In addition, the size of the bottomed hole 40 can be at least two rows of stitches in the warp direction D2 and at least two wales in the weft direction D1. A double-sided knitted circular fabric having the above-mentioned bottomed hole 40 can also be formed. A double-sided knitted circular fabric having a bottomed hole 40 of a more complex shape can also be formed.

[0110] The attachment base 110 of the knitted fabric retaining attachment 100 is not limited to the combination of three members (111, 113 and 115). For example, the attachment base 110 may include an integrally formed member that makes the horizontal plane portion 111 and the vertical shaft portion 113 inseparable, or an integrally formed member that makes the vertical shaft portion 113 and the wire support portion 115 inseparable. Of course, the attachment base 110 may be an integrally formed member that makes the three parts (111, 113 and 115) inseparable.

[0111] The shape of the spring wire 120 may be appropriately modified as long as the spring wire 120 includes the fabric holding portion 123. For example, the spring wire 120 may be composed of the fabric holding portion 123 and a connecting portion oriented from the attachment base 110 and connected to the fabric holding portion 123, the longitudinal direction of the fabric holding portion 123 being different from the longitudinal direction of the attachment base 100.

[0112] (6) Conclusion

[0113] As described above, according to the present invention, in various embodiments, there can be provided a novel double-sided circular knitted fabric capable of preventing debris from penetrating from surface holes into the space between the front knitted fabric and the back knitted fabric in an inexpensive manner, a knitted product including the double-sided circular knitted fabric, a method for manufacturing the double-sided circular knitted fabric, and a knitted fabric retaining attachment used in the manufacturing method, etc. Of course, the configuration consisting of the components in each independent claim can produce the above-mentioned main operations and effects.

[0114] It is also possible to implement a configuration formed by exchanging or combining the components disclosed in the above examples with each other, a configuration formed by exchanging or combining components in the related art and the components disclosed in the above examples with each other, etc. The present invention implicitly encompasses these configurations, etc.

[0115] CROSS-REFERENCE TO RELATED APPLICATIONS

[0116] This application is related to Japanese Patent Application No. 2023-183055 filed on October 25, 2023, the entire disclosure of which is expressly incorporated herein by reference.

[0117] Explanation of Reference Symbols

[0118] 1 ... double knit circular knitted fabric;

[0119] 10 ... front knitted fabric; 11 ... front yarn; 12 ... stitch structure; 13 ... surface; 14 ... pattern;

[0120] 20 ...back knit; 21 ...back yarn; 22 ...stitch structure;

[0121] 30 ... piping structure; 31 ... piping yarn;

[0122] 40 ... with bottom hole; 41 ... opening; 42 ... bottom; 43 ... side; 44 ... with bottom groove;

[0123] 50 ... knitted fabrics; 51 ... knitted yarns;

[0124] 100 ... Knitted fabric retaining attachment;

[0125] 110 ...attachment base;

[0126] 120 ...spring steel wire; 123 ...fabric retaining portion;

[0127] 200 ...Double Knit Circular Knitting Machine;

[0128] 210 ... syringe; 211 ... syringe needle;

[0129] 220 ... needle dial; 221 ... dial needle;

[0130] 230 ...needle selector;

[0131] 240 ...support body; 241 ...upper surface;

[0132] A1 ...area; A2 ...needle advancement and retraction range;

[0133] D1 ... latitudinal direction; D2 ... longitudinal direction;

[0134] d1 ...diameter;

[0135] F1 to F4 ...feeder;

[0136] L1 ...length;

[0137] P1 ... hold position;

[0138] ST1 ...maintaining step; ST2 ...controlling step.

Claims

1. A double-sided circular knitted fabric comprising: a front knitted fabric having a first stitch structure of a front yarn; a back knitted fabric having a second stitch structure of a back yarn; and A piping structure, in which the front knitted fabric and the back knitted fabric are piping together using piping yarns, wherein: The front knitted fabric has bottomed holes that are recessed from the surface of the front knitted fabric and connected to the back knitted fabric, and The front yarn drawn into the back knitted fabric is located on the side of the bottomed hole.

2. The double knit circular fabric according to claim 1, wherein: The front knitted fabric has a plurality of bottomed holes, and The surface of the front knitted fabric has the pattern of the bottomed holes.

3. The double knit circular fabric according to claim 1, wherein: The front knitted fabric has a plurality of bottomed holes, and The bottomed hole includes a bottomed groove, and the longitudinal direction of the bottomed groove is oriented along the meridian direction.

4. A knitted product comprising the double-knit circular knitted fabric according to any one of claims 1 to 3.

5. A method of manufacturing a double knit circular knitted fabric using a double knit circular knitting machine, the double knit circular knitting machine comprising: A syringe having a cylinder needle arranged thereon, a needle dial having a dial needle arranged thereon, a needle selector, and a support body located outside the syringe, the method comprising: A holding step of holding the knitted fabric using a spring steel wire to prevent the knitting yarn from being tangled at a holding position between the cylinder needle and the dial needle, the spring steel wire leading from an attachment base attached to the support body to the holding position; and Control step: Control the operation of the cylinder needle and the dial needle and the supply of the knitting yarn so as to knit the double-sided knitted circular fabric, the knitting yarn includes a front yarn, a back yarn and a piping yarn, the double-sided knitted circular fabric includes: a front knitted fabric having a first stitch structure of the front yarn, a back knitted fabric having a second stitch structure of the back yarn, and a piping structure, in which the front knitted fabric and the back knitted fabric are piping together using the piping yarn, the front knitted fabric has a bottomed hole recessed from the surface of the front knitted fabric and connected to the back knitted fabric, the front yarn is pulled into the back knitted fabric, and the front yarn is located on the side of the bottomed hole.

6. The method according to claim 5, wherein: The cross section of the spring steel wire is an ellipse with a maximum diameter of 0.7 mm to 1.2 mm, including a circle with a cross section diameter of 0.7 mm to 1.2 mm.

7. A knitted fabric retaining attachment for attachment to a double jersey circular knitting machine, the double jersey circular knitting machine comprising: A needle cylinder with a cylinder needle arranged thereon, a needle dial with a dial needle arranged thereon, a needle selector, and a support body located outside the needle cylinder, the knitted fabric holding attachment holding a knitted fabric to prevent the knitted yarn from being tangled at a holding position between the cylinder needle and the dial needle, the knitted fabric holding attachment comprising: an attachment base for attachment to the support; and A spring steel wire leads from the attachment base to the holding location to hold the knitted fabric at the holding location.

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