Feeder and method for producing double knit fabric

Abstract

A feeder (30) comprises a one-side yarn feeding port (31A) that is open to a surface that is on the radially inward side of a dial on a main body. The one-side yarn feeding port (31A) guides a knitting yarn that is knitted as a one-side knitted structure (11A) toward a knit region of a cylinder needle (41B) that is set on the needle bed (41A) of a cylinder (41). The feeder (30) comprises a guide groove (30A) that guides a knitting yarn that is knitted as an other-side plating structure (12E) or a one-side plating structure (11E) toward a knit region of a dial needle (42B) or the knit region of the cylinder needle (41B). The feeder (30) comprises a protruding piece (32) that protrudes radially outward from the main body. The feeder (30) comprises an other-side yarn feeding port (32A) that is provided to the protruding piece (32) and guides a knitting yarn that is knitted as an other-side knitted structure (12A) toward the knit region of the dial needle (42B) when said knitting yarn is passed through.

Description

Feeder and method for producing double knit fabric

[0001] The present disclosure relates to a feeder applicable to a dial-cylinder type circular knitting machine, which is a device for producing double knit fabrics, and a method for producing double knit fabrics using the circular knitting machine.

[0002] In this disclosure, a "double knit fabric" has one side knit fabric constituting one surface and the other side knit fabric constituting the other surface. The one side knit fabric and the other side knit fabric are connected by a connecting yarn. Some double knit fabrics have a five-layer structure (see, for example, JP 2022-023308 A). In the five-layer structure, the one side knit fabric and the other side knit fabric each have a ground knit structure and a plating structure. The plating structure of the one side knit fabric and the plating structure of the other side knit fabric are interwoven. The ground knit structure is made of spun yarn made of staple cotton. The plating structure is made of elastic polyester yarn. The five-layer double knit fabric described in JP 2022-023308 A is produced using a dial-cylinder type circular knitting machine. Specifically, the one side knit fabric and the other side knit fabric are knitted with dial needles and cylinder needles, respectively.

[0003] The knitting yarn to be knitted as the ground knitting structure and the knitting yarn to be knitted as the plating structure are fed from separate yarn feeding routes toward one knit region. During this process, the direction of the yarn path of the knitting yarn may be reversed due to factors such as the inclusion of so-called "fibers" (aggregates of fibers that have fallen off the spun yarn). In this case, a defective knitted fabric is knitted in which the plating structure appears where the ground knitting structure should appear, and the ground knitting structure appears where the plating structure should appear.

[0004] One known technology that can reduce the risk of knitting defective knitted fabrics is the yarn feed guide (commonly referred to as a "feeder") technology described in JP-A-11-269744. In this technology, a yarn feeder port for inserting cotton yarn and an arc-shaped cutout portion are provided below the yarn feed guide of a circular knitting machine. A concave guide piece for guiding the elastic fiber yarn is provided near the cutout portion.

[0005] When the yarn feed guide described in JP 11-269744 A is applied to a dial-cylinder type circular knitting machine, it can only guide the knitting yarn fed to the cylinder needles. As a result, when producing the five-layer double knit fabric described in JP 2022-023308 A, there remains a risk of defective products being knitted. Specifically, there is a risk that a plating texture will appear where a ground knit texture should appear, and that a ground knit texture will appear where a plating texture should appear.

[0006] The present disclosure makes it possible to reduce the risk of producing defective products when producing double knit fabrics in which one side knit fabric and the other side knit fabric are each constructed by combining a base knit fabric with a plating fabric.

[0007] According to one feature of the present disclosure, there is provided a feeder applicable to a dial-cylinder type circular knitting machine, which is an apparatus for producing double knit fabrics. The double knit fabric has a configuration in which a one-side knitted fabric constituting one surface and an other-side knitted fabric constituting the other surface are joined together by a connecting yarn. The one-side knitted fabric has a one-side ground knitted structure exposed on one side and a one-side plating structure aligned along the other surface of the one-side ground knitted structure. The other-side knitted fabric has an other-side ground knitted structure exposed on the other side and an other-side plating structure aligned along the one surface of the other-side ground knitted structure. The feeder has a main body set at a position radially outward of the dial of the cylinder of the circular knitting machine. The feeder has a one-side yarn feed port opening on a surface of the main body that is radially inward of the dial. When a knitting yarn to be knitted as the one-side ground knitting structure is passed through from the radially outer side, this one-side yarn feeder guides the knitting yarn toward the knit area of ​​the cylinder needles set on the needle bed of the cylinder. The feeder also has a guide groove that guides a knitting yarn to be knitted as the other-side plating structure or the one-side plating structure toward the knit area of ​​the dial needles set on the needle bed of the dial or the knit area of ​​the cylinder needles. The feeder also has an overhanging piece that overhangs radially outward from the main body and forms at least a part of the wall of the guide groove. The feeder also has a other-side yarn feeder that is provided on the overhanging piece and guides the knitting yarn to be knitted as the other-side ground knitting structure toward the knit area of ​​the dial needles when the knitting yarn is passed through.

[0008] The above-mentioned feeder can be used in a dial-cylinder type circular knitting machine to supply a knitting yarn to be knitted as a one-side knitting fabric or a knitting yarn to be knitted as an other-side knitting fabric. When the feeder supplies a knitting yarn to be knitted as a other-side knitting fabric, the other-side yarn feeder of the feeder guides the knitting yarn to be knitted as a one-side ground knitting structure toward the knitting area of ​​the dial needles. The guide groove of the feeder guides the knitting yarn to be knitted as a other-side plating structure toward the knitting area of ​​the dial needles. This reduces the risk of knitting a defective product. Specifically, a defective product is one in which an other-side plating structure appears in a place where an other-side ground knitting structure should appear, and an other-side ground knitting structure appears in a place where an other-side plating structure should appear. Furthermore, when the feeder supplies a knitting yarn to be knitted as a one-side knitting fabric, the one-side yarn feeder of the feeder guides the knitting yarn to be knitted as a one-side ground knitting structure toward the knitting area of ​​the cylinder needles. The guide groove of the feeder guides the knitting yarn knitted as a one-side plating structure toward the knitting area of ​​the cylinder needles. This allows the feeder to reduce the risk of knitting a defective product. A defective product is specifically a defective product in which a one-side plating structure appears where a one-side ground knit structure should appear, and a one-side ground knit structure appears where a one-side plating structure should appear. Due to these actions, the feeder can reduce the risk of knitting a defective product when producing a double knit fabric in which the one-side knit fabric and the other-side knit fabric are each configured by combining a plating structure with a ground knit structure.

[0009] According to another aspect, the extension piece covers the dial needle release area from the side where the dial needle receives the knitting yarn. The dial needle release area is an area in a circular knitting machine where the dial needle is released radially outward to receive the knitting yarn. The other-side yarn feed port is open at the end surface of the extension piece that faces the dial needle release area.

[0010] In the above-mentioned circular knitting machine, the knitting yarn to be knitted as the other-side ground knit structure is received by the dial needle in the dial needle outlet area and drawn toward the knit area of ​​the dial needle. According to the above-mentioned feeder, the knitting yarn passed through the other-side yarn feeder is drawn to the dial needle outlet area. Therefore, the dial needle of the circular knitting machine can receive the knitting yarn as is and draw it into the knit area of ​​the dial needle. The yarn path of the knitting yarn from the other-side yarn feeder to the knit area of ​​the dial needle has a guide-free portion where the knitting yarn is not guided by other components. According to this configuration, the guide-free portion can be shortened, further reducing the risk of the direction of extension of the knitting yarn path being reversed.

[0011] According to another aspect, the other-side yarn feeder is inclined radially inward toward the dial needle outlet area.

[0012] In the above circular knitting machine, the knitting yarn is drawn into the knitting region of the dial needle from the radially outer side to the radially inner side of the dial. With the above feeder, the knitting yarn passed through the other yarn feeder is extended in a state inclined radially inward toward the dial needle outlet region. This allows the dial needle to draw the knitting yarn more smoothly.

[0013] According to another aspect, the other-side yarn feeder extends at a first inclination angle relative to the needle bed of the dial, and the one-side yarn feeder extends at a second inclination angle relative to the needle bed of the dial that is inclined radially inward toward the needle bed of the dial and that is smaller than the first inclination angle.

[0014] According to another aspect, the guide groove is inclined radially inward toward the needle bed of the dial and extends at a third inclination angle relative to the needle bed of the dial that is smaller than the first inclination angle and larger than the second inclination angle.

[0015] According to another aspect, the guide groove is located between the one-side yarn feeder and the other-side yarn feeder. The guide groove, the one-side yarn feeder, and the other-side yarn feeder are spaced apart from each other.

[0016] According to another aspect, there is provided a method for producing the double knit fabric described below using a dial-cylinder type circular knitting machine. The double knit fabric has a configuration in which a one-side knitted fabric constituting one surface and an other-side knitted fabric constituting the other surface are joined together by a connecting yarn. The one-side knitted fabric has a one-side ground knit structure exposed on one side and a one-side plating structure aligned along the other surface of the one-side ground knit structure. The other-side knitted fabric has an other-side ground knit structure exposed on the other side and an other-side plating structure aligned along the one surface of the other-side ground knit structure. In the method for producing the double knit fabric, the above-mentioned first feeder and second feeder are applied to the circular knitting machine. In the method for producing the double knit fabric, a knitting yarn to be knitted as the one-side ground knit structure is passed through one-side yarn feeder of the first feeder from the radially outer side. A knitting yarn to be knitted as a one-side plating structure is hung in the guide groove of the first feeder. A knitting yarn to be knitted as a other-side plating structure is hung in the guide groove of the second feeder. A knitting yarn to be knitted as a other-side ground knit structure is passed through the other-side yarn feeder of the second feeder. In this state, a double knit fabric is produced by a knitting process in which these knitting yarns are knitted using a circular knitting machine.

[0017] According to the above method, the other-side yarn feeder of the second feeder guides the knitting yarn to be knitted as the other-side ground knitting structure toward the knit area of ​​the dial needles. The guide groove of the second feeder guides the knitting yarn to be knitted as the other-side plating structure toward the knit area of ​​the dial needles. As a result, the second feeder reduces the risk of knitting a defective product. Specifically, a defective product is one in which the other-side plating structure appears in a position where the other-side ground knitting structure should appear, and the other-side ground knitting structure appears in a position where the other-side plating structure should appear. Furthermore, the one-side yarn feeder of the first feeder guides the knitting yarn to be knitted as the one-side ground knitting structure toward the knit area of ​​the cylinder needles. The guide groove of the first feeder guides the knitting yarn to be knitted as the one-side plating structure toward the knit area of ​​the cylinder needles. As a result, the first feeder reduces the risk of knitting a defective product. Specifically, the defective products are those in which one-side plating texture appears in a place where one-side ground knitting texture should appear, and the other-side ground knitting texture appears in a place where one-side plating texture should appear. Due to these effects, the method for producing double knit fabrics described above can reduce the risk of knitting defective double knit fabrics.

[0018] In another aspect of the method for producing a double knit fabric, a guide member for guiding a knitting yarn is attached to a feeder. The knitting yarn guided by this guide member is further guided by one of a yarn feeder on one side, a guide groove, or a yarn feeder on the other side of the feeder. In this state, a knitting step is carried out.

[0019] In a dial-cylinder type circular knitting machine, the number of feeders used is directly related to the knitting speed of the knitted fabric. Therefore, it is generally considered preferable to knit with a large number of feeders arranged at high density. However, as the arrangement density of feeders used in a circular knitting machine increases, the space for arranging the yarn paths of the knitting yarns guided by each feeder becomes narrower. This makes it difficult to accurately determine the direction in which the yarn paths of the knitting yarns extend. In contrast, according to the above method, the knitting yarn guided by one of the yarn feeders, the guide groove, or the other yarn feeder of the feeder is guided by a guide member attached to the feeder. This allows the space for arranging the yarn paths of the knitting yarns guided by the feeder to be expanded. As a result, the risk of the direction in which the yarn paths of the knitting yarns guided by the feeders are reversed can be further reduced.

[0020] In another aspect of the method for producing a double knit fabric, the knitting step is carried out in a state where a guide member is disposed upstream of the feeder in the direction of rotation of the cylinder of the circular knitting machine.

[0021] In a dial-cylinder type circular knitting machine, the knitting yarn is fed from the upstream side to the downstream side in the direction of rotation of the cylinder of the circular knitting machine to the knitting region of the cylinder needles or dial needles. According to the above method, the yarn path arrangement space of the knitting yarn guided by the feeder is expanded toward the upstream side in the direction of rotation of the cylinder of the circular knitting machine. As a result, the direction in which the yarn path of the knitting yarn from the guide member to the feeder extends is aligned with the direction in which the yarn path of the knitting yarn from the feeder to the knitting region extends. This reduces damage to the knitting yarn caused by friction with the feeder.

[0022] In another aspect of the method for producing a double knit fabric, a third feeder and a fourth feeder are applied to the circular knitting machine, and a knitting process is carried out with knitting yarns for constructing the binder yarn structure being threaded through the third feeder and the fourth feeder, respectively.

[0023] In another aspect of the method for producing a double knit fabric, a feeder set including a first feeder, a second feeder, a third feeder, and a fourth feeder is applied to a circular knitting machine. With the circular knitting machine adjusted to interlock knitting and with the knitting settings F1 to F6 below set, a knitting process is carried out. F1: Knitting setting for a connecting yarn passed through the third feeder. F2: Knitting setting for a jersey knit with cylinder needles for a knitting yarn passed through one yarn feeder of the first feeder. F3: Knitting setting for a jersey knit with dial needles for a knitting yarn passed through the other yarn feeder of the second feeder. F4: Knitting setting for a connecting yarn passed through the fourth feeder. F5: Knitting setting for a jersey knit with cylinder needles for a knitting yarn hung through the guide groove of the first feeder. F6: Knitting setting for a jersey knit with dial needles for a knitting yarn hung through the guide groove of the second feeder.

[0024] In another aspect of the method for producing a double knit fabric, a circular knitting machine is adjusted to interlock knitting, and knitting steps F1 to F4 are performed with the following knitting settings F1 to F4. F1: Knitting setting for a connecting yarn passed through the third feeder. F2: Knitting setting for a connecting yarn passed through the fourth feeder. F3: Knitting setting for a bare jersey knit with a dial needle using a knitting yarn passed through the other yarn feeder of the second feeder and a knitting yarn hung in the guide groove of the second feeder. For example, the two knitting yarns are guided into the knitting area of ​​the dial needles in a pulled-together state. F4: Knitting setting for a bare jersey knit with a cylinder needle using a knitting yarn passed through one yarn feeder of the first feeder and a knitting yarn hung in the guide groove of the first feeder. For example, the two knitting yarns are guided into the knitting area of ​​the cylinder needles in a pulled-together state.

[0025] According to the present disclosure, when producing a double knit fabric in which one side knit fabric and the other side knit fabric are each constructed by combining a base knit fabric with a plating fabric, the risk of knitting defective products can be reduced.

[0026] A "pulled" state refers to, for example, a state in which multiple yarns are bundled together so that they can be handled as if they were a single yarn. Jersey knitting is, for example, a type of "weft knitting." In jersey knitting, a knitted fabric is created by repeatedly inserting the next "loop" of knitting yarn that appears on the front or back side into a loop that is lined up in the weft direction (face knitting) so that it appears on the front or back side. Bare jersey knitting is a type of "jersey knitting." Bare jersey knitting is jersey knitting made using yarn that is "pulled" state.

[0027] The knit area is where the dial or cylinder needle forms a new loop of yarn after receiving it. For example, the knit area of ​​a dial needle is the area that does not overlap with the dial needle exit area. The knit area of ​​a dial needle is the area near where the dial needle receives the yarn, retracts, and then returns slightly. Knitting techniques include knit, tuck, welt, and miss.

[0028] Fig. 1 is an enlarged cross-sectional view of a main part showing a schematic configuration of a double knit fabric produced by a method for producing a double knit fabric according to a first embodiment. Fig. 2 is a photograph of a main part of a circular knitting machine which is an apparatus for producing the double knit fabric shown in Fig. 1. Fig. 3 is a front view of a second feeder unit shown in Fig. 2. Fig. 4 is a rear view of a second feeder unit shown in Fig. 2. Fig. 5 is a left side view of a second feeder unit shown in Fig. 2. Fig. 6 is a right side view of a second feeder unit shown in Fig. 2. Fig. 7 is a plan view of a second feeder unit shown in Fig. 2. Fig. 8 is a bottom view of a second feeder unit shown in Fig. 2. Fig. 9 is a knitting diagram for explaining a method for producing a double knit fabric according to the first embodiment. Fig. 10 is a knitting diagram for explaining a method for producing a double knit fabric according to the second embodiment.

[0029] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings.

[0030] First Embodiment First, the configuration of a double knit fabric 10 produced by a method for producing a double knit fabric according to a first embodiment will be described with reference to Fig. 1. This double knit fabric 10 has a five-layer structure. Specifically, the double knit fabric 10 has one side knit fabric 11 that forms one surface, and another side knit fabric 12 that forms the other surface. The one side knit fabric 11 and the other side knit fabric 12 are connected together by a connecting yarn 10A.

[0031] The one side knitted fabric 11 has a one side ground knitted structure 11A, which is a weft knitted structure, exposed on one side. In this embodiment, the one side ground knitted structure 11A is a circular knitted plain structure with the front side 11B facing one side and the back side 11C facing the other side. This plain structure is made of spun yarn 10C.

[0032] The spun yarn 10C has the properties of a fancy yarn, with thick and thin portions. Therefore, the loops 11D in the plain weave of the one-side ground knit structure 11A have variations in the size of the holes. In this embodiment, the spun yarn 10C is made by spinning cotton, a natural staple fiber, and has knots (not shown) derived from this cotton material in the thick portions. The spun yarn 10C also has knots resulting from uneven spinning of the fiber.

[0033] Furthermore, the one side knitted fabric 11 has a one side plating structure 11E aligned along the other side surface (i.e., the back surface 11C) of the one side ground knitted structure 11A. This one side plating structure 11E is composed of an elastic yarn 10D that is more elastically deformable than the spun yarn 10C that constitutes the one side ground knitted structure 11A. In this embodiment, the elastic yarn 10D is a filament yarn having polyurethane-based filaments.

[0034] The other side knitted fabric 12 has a other side ground knitted structure 12A, which is a weft knitted structure, exposed on the other side. In this embodiment, the other side ground knitted structure 12A is a circular knitted plain stitch structure with the front surface 12B facing the other side and the back surface 12C facing the one side. This plain stitch structure is made of the same type of spun yarn 10E as the spun yarn 10C that forms the one side ground knitted structure 11A. For this reason, the loops 12D in the plain stitch structure of the other side ground knitted structure 12A will vary in size.

[0035] Furthermore, the other side knitted fabric 12 has a other side plating structure 12E aligned along one surface (i.e., the back surface 12C) of the other side ground knitted structure 12A. In this embodiment, the other side plating structure 12E is composed of elastic yarn 10F of the same type as the elastic yarn 10D that constitutes the one side plating structure 11E. In other words, the elastic yarn 10F that constitutes the other side plating structure 12E is more easily elastically deformed than the spun yarn 10E that constitutes the other side ground knitted structure 12A.

[0036] The connecting yarn 10A is a false twist yarn having crimped filaments. The filaments are long enough to form a yarn without spinning multiple filaments together. In this embodiment, the connecting yarn 10A is a false twist yarn having multiple nylon filaments bundled together.

[0037] The double knit fabric 10 can be produced by a dial-cylinder type circular knitting machine 40 (see FIG. 2) adjusted to have interlocking weaves. In other words, the circular knitting machine 40 is a device for producing the double knit fabric 10. As shown in FIG. 2, this circular knitting machine 40 employs a first feeder 20 and a second feeder 30, each of which is a feeder according to the first embodiment, and feeders 40A and 40B, which are conventionally known feeders. In this embodiment, the feeders are periodically arranged in the order of feeder 40B, feeder 40A, second feeder 30, first feeder 20, feeder 40B, etc., as viewed in the direction of cylinder rotation of the circular knitting machine 40 (from left to right in FIG. 2).

[0038] Here, the second feeder 30 has exactly the same configuration as the first feeder 20. Therefore, in the following, detailed explanations of the components of the first feeder 20 and the second feeder 30 will be given by representing the components of the second feeder 30. The components of the first feeder 20 will be assigned the same reference numerals as those assigned to the components of the second feeder 30, with the tens digit replaced by "2," and detailed explanations thereof will be omitted.

[0039] The feeder 40A is a conventional feeder capable of setting only one yarn path for the knitting yarn. The feeder 40A feeds the connecting yarn 10A as the knitting yarn to the knitting region 41E located downstream of the feeder 40A in the direction of rotation of the cylinder.

[0040] The feeder 40B has the same configuration as the feeder 40A. The feeder 40B uses the connecting yarn 10A as a knitting yarn and supplies the connecting yarn 10A to a knit region 42E located downstream of the feeder 40B in the direction of cylinder rotation.

[0041] As shown in FIGS. 3 to 8, the second feeder 30 includes a main body 31, a handle 33, and a guide member 33A.

[0042] The main body 31 is plate-shaped. As shown in Fig. 2, the main body 31 is set by screws in a position above the needle bed 42A of the dial 42 on which the dial needles 42B are set in the circular knitting machine 40. As shown in Fig. 6, the main body 31 is set in a position radially outward of the dial 42 (to the left in Fig. 6) from the needle bed 41A on which the cylinder needles 41B are set in the cylinder 41 of the circular knitting machine 40. Hereinafter, the state in which the main body 31 is set in the circular knitting machine 40 will also be simply referred to as the "set state." Furthermore, below, the up, down, left, right, front, and rear directions of each component of the second feeder 30 will be described in terms of the directions when the main body 31 is in the set state.

[0043] 3 to 7, an elongated hole 31B is provided at the top of the main body 31 for screwing the main body 31 to the circular knitting machine 40. A nut portion 31C is provided below the elongated hole 31B in the main body 31 for threading a male screw (for example, the handle 33 shown in FIG. 5) onto the main body 31. A one-side yarn feeder 31A that penetrates the main body 31 from the upper left front side to the lower right rear side is provided below the nut portion 31C in the main body 31. A protruding piece 32 is provided at the lower edge of the main body 31, protruding from the lower edge radially outward from the dial 42 (see FIG. 6).

[0044] The one-side yarn feeder 31A is open at the rear surface (the surface on the near side of the paper as viewed in FIG. 4) of the main body 31. This rear surface is the surface that is on the radially inner side of the dial 42 in the set state, as shown in FIG.

[0045] The guide member 33A is a conventionally known loop guide of a type that is fixed to another member by screws. In this embodiment, the guide member 33A is disposed so that its eyelet (a hole through which a linear member such as a yarn is passed) is positioned on an extension of the axis of the one-side yarn feeder 31A, as shown in FIG. 3 .

[0046] The handle 33 is a conventionally known circular support (an external thread with a head formed in a long cylindrical shape). The handle 33 secures the guide member 33A to the main body 31 by screwing the guide member 33A to the nut portion 31C of the main body 31. The head of the handle 33 also functions as a knob for handling the second feeder 30 and as a support for attaching other members (for example, the guide member 33B shown in FIG. 2) to the second feeder 30. In this embodiment, the guide member 33B is a conventionally known roller guide with a fixing device.

[0047] The protruding piece 32 is plate-shaped. As shown in Fig. 6, the protruding piece 32 protrudes perpendicularly from the lower edge of the main body 31. In the set state, the protruding piece 32 covers the dial needle exit region 42D from the side that receives the knitting yarn (the upper side in Fig. 6). The dial needle exit region 42D is a region in the circular knitting machine 40 where the dial needles 42B are extended radially outward to receive the knitting yarn (see the spun yarn 10E in Fig. 2). The dial needles 42B receive the knitting yarn from the upper side.

[0048] A guide groove 30A is provided at the base portion of the overhanging piece 32 that overhangs from the main body 31, extending from below the position where one yarn feeder 31A is opened (see FIG. 3) on the front surface of the main body 31 toward the lower right rear side. In this embodiment, the guide groove 30A has one wall (the upper right side in FIG. 6) formed by the main body 31, and the opposite wall (the lower left side in FIG. 6) formed by the overhanging piece 32.

[0049] 3, 6, and 8, a second-side yarn feeder 32A is provided in a portion of the overhanging piece 32 forward of the guide groove 30A, penetrating the overhanging piece 32 from the upper front to the lower rear. As shown in Fig. 8, this second-side yarn feeder 32A opens at the end face on the lower side (the front side of the paper in Fig. 8) of the overhanging piece 32. As shown in Fig. 6, this end face is the face that faces the dial needle-out area 42D in the set state. Furthermore, the second-side yarn feeder 32A is provided so as to incline radially inward toward the dial needle-out area 42D in the set state.

[0050] Next, a method for producing the above-described double knit fabric 10 (hereinafter, simply referred to as the "method" in the description of the first embodiment) will be described. In the method, a setting step is performed in which knitting yarn is set on an interlocking circular knitting machine 40 (see FIG. 2) to which a first feeder 20, a second feeder 30, and feeders 40A and 40B are respectively applied. In this method, the knitting yarn is set in the setting step. In the knitting step, the double knit fabric 10 is produced by knitting using the circular knitting machine 40.

[0051] Referring to the main parts of the circular knitting machine 40 shown in Figure 2, in the setting process, the spun yarn 10C is passed through the eyelet of the guide member 23A and the one-side yarn feeder 21A of the first feeder 20, in that order. The spun yarn 10C is a knitting yarn that will be knitted as the one-side ground knit structure 11A. At this time, the one-side yarn feeder 21A guides the spun yarn 10C toward the knit region 41C as the spun yarn 10C is passed from the radially outer side of the dial 42. Here, the knit region 41C is a knit region of the cylinder needles 41B set on the needle beds 41A of the cylinder 41 in the circular knitting machine 40, where the spun yarn 10C and the elastic yarn 10D are knitted in a pulled-together state.

[0052] In the setting process, the elastic yarn 10D is wound around the roller of the guide member 23B and the guide groove 20A of the first feeder 20, in that order. The elastic yarn 10D is a knitting yarn that is knitted as a one-side plating structure 11E. At this time, the guide groove 20A guides the wound elastic yarn 10D toward the knit region 41C. As shown in Figure 2, the operation of winding the elastic yarn 10D around the roller of the guide member 23B may be omitted.

[0053] Referring to the main parts of the circular knitting machine 40 shown in Figure 2, in the setting step, the spun yarn 10E is passed from above through the other-side yarn feeder 32A of the second feeder 30 shown in Figure 3. The spun yarn 10E is a knitting yarn that will be knitted as the other-side ground knit structure 12A. At this time, the other-side yarn feeder 32A guides the passed spun yarn 10E toward the knit region 42C shown in Figure 2. The knit region 42C is a knit region of the dial needles 42B set on the needle beds 42A of the dial 42 in the circular knitting machine 40, where the spun yarn 10E and the elastic yarn 10F are knitted in a pulled-together state.

[0054] Referring to the main parts of the circular knitting machine 40 shown in Figure 2, in the setting step, the elastic yarn 10F is wound around the roller of the guide member 33B and the guide groove 30A of the second feeder 30 shown in Figure 6, in that order. The elastic yarn 10F is a knitting yarn that will be knitted as the other-side plating structure 12E. At this time, the guide groove 30A guides the wound elastic yarn 10F toward the knit region 42C shown in Figure 2. The operation of winding the elastic yarn 10F around the roller of the guide member 33B may be omitted.

[0055] 2, in the setting step, a connecting yarn 10A serving as a knitting yarn is passed through a feeder 40A. At this time, the feeder 40A guides the passed connecting yarn 10A toward the knit region 41E.

[0056] 2, in the setting step, a connecting yarn 10A different from the connecting yarn 10A passed through the feeder 40A is passed through the feeder 40B as a knitting yarn. At this time, the feeder 40B guides the passed connecting yarn 10A toward the knit region 42E.

[0057] The knitting process is carried out after the setting process is completed. The knitting settings in the knitting process are as shown in the knitting diagrams F1 to F6 in Fig. 9. F1 is a knitting diagram showing the knitting settings for the connecting yarn 10A passed through the feeder 40A. F4 is a knitting diagram showing the knitting settings for the connecting yarn 10A passed through the feeder 40B. F2 is a knitting diagram showing the knitting settings for the spun yarn 10C knitted as one side ground knitting structure 11A. F5 is a knitting diagram showing the knitting settings for the elastic yarn 10D knitted as one side plating structure 11E. F3 is a knitting diagram showing the knitting settings for the spun yarn 10E knitted as the other side ground knitting structure 12A. F6 is a knitting diagram showing the knitting settings for the elastic yarn 10F knitted as the other side plating structure 12E.

[0058] The feeder of the present disclosure can be applied as a first feeder 20 that supplies a knitting yarn to be knitted as a one-side knitted fabric 11 in a dial-cylinder type circular knitting machine 40. Alternatively, the feeder of the present disclosure can be applied as a second feeder 30 that supplies a knitting yarn to be knitted as a other-side knitted fabric 12 in a circular knitting machine 40. A: When the feeder of the present disclosure is the second feeder 30, the second feeder 30 guides the spun yarn 10E toward the knit region 42C of the dial needles 42B via the other-side yarn feeder 32A. The spun yarn 10E is a knitting yarn to be knitted as a other-side ground knitting structure 12A. The second feeder 30 also guides the elastic yarn 10F toward the knit region 42C via the guide groove 30A. The elastic yarn 10F is a knitting yarn to be knitted as a other-side plating structure 12E. This reduces the risk of knitting a defective product using the second feeder 30. Specifically, the defective product is a defective product in which the other side plating structure 12E appears where the other side ground knitting structure 12A should appear, and the other side ground knitting structure 12A appears where the other side plating structure 12E should appear.

[0059] B: When the feeder of the present disclosure is the first feeder 20, the first feeder 20 guides the spun yarn 10C toward the knit region 41C of the cylinder needles 41B via the one-side yarn feeder 21A. The spun yarn 10C is a knitting yarn that is knitted as the one-side ground knitting structure 11A. The first feeder 20 also guides the elastic yarn 10D toward the knit region 41C via the guide groove 20A. The elastic yarn 10D is a knitting yarn that is knitted as the one-side plating structure 11E. This reduces the risk of the first feeder 20 knitting a defective product. Specifically, a defective product is one in which the one-side plating structure 11E appears in the place where the one-side ground knitting structure 11A should appear, and the one-side ground knitting structure 11A appears in the place where the one-side plating structure 11E should appear. Due to the actions of A and B above, the feeder of the present disclosure can reduce the risk of producing defective products when producing a double knit fabric 10 in which one side knit fabric 11 and the other side knit fabric 12 are each configured by combining a base knit fabric with a plating fabric.

[0060] In the above-described circular knitting machine 40, the spun yarn 10E is received by the dial needle 42B in the dial needle feed area 42D and drawn toward the knit area 42C of the dial needle 42B. The spun yarn 10E is the knitting yarn to be knitted as the other-side ground knit structure 12A. The second feeder 30 delivers the spun yarn 10E, which is the knitting yarn passed through the other-side yarn feeder 32A, to the dial needle feed area 42D. Therefore, the dial needle 42B of the circular knitting machine 40 can receive the spun yarn 10E as is and draw it into the knit area 42C. The yarn path of the spun yarn 10E from the other-side yarn feeder 32A to the knit area 42C of the dial needle 42B has a guide-free portion where the spun yarn 10E is not guided by other components. This configuration shortens the guide-free portion. As a result, the risk of the extension direction of the yarn path of the spun yarn 10E being reversed can be further reduced.

[0061] In the above-described circular knitting machine 40, the dial needles 42B draw the spun yarn 10E toward the knit region 42C in a direction from the radially outer side to the radially inner side of the dial 42. The second feeder 30 extends the spun yarn 10E toward the dial needle outlet region 42D in a state inclined radially inward. The spun yarn 10E is a knitting yarn that is passed through the other yarn feeder 32A. This allows the dial needles 42B to draw the spun yarn 10E more smoothly.

[0062] According to the above-described method, the second feeder 30 guides the spun yarn 10E toward the knit region 42C of the dial needle 42B by the other-side yarn feeder 32A. The spun yarn 10E is a knitting yarn to be knitted as the other-side ground knitting structure 12A. Furthermore, the second feeder 30 guides the elastic yarn 10F toward the knit region 42C by the guide groove 30A. The elastic yarn 10F is a knitting yarn to be knitted as the other-side plating structure 12E. This reduces the risk of knitting a defective product. Specifically, a defective product is one in which the other-side plating structure 12E appears in a position where the other-side ground knitting structure 12A should appear, and the other-side ground knitting structure 12A appears in a position where the other-side plating structure 12E should appear.

[0063] The first feeder 20 guides the spun yarn 10C toward the knit area 41C of the cylinder needles 41B using the one-side yarn feeder 21A. The spun yarn 10C is a knitting yarn that will be knitted as the one-side ground knit structure 11A. Furthermore, the first feeder 20 guides the elastic yarn 10D toward the knit area 41C using the guide groove 20A. The elastic yarn 10D is a knitting yarn that will be knitted as the one-side plating structure 11E. This reduces the risk of the first feeder 20 knitting a defective product. Specifically, a defective product is one in which the one-side plating structure 11E appears in a position where the one-side ground knit structure 11A should appear, and one-side ground knit structure 11A appears in a position where the one-side plating structure 11E should appear. Due to these effects, the present method can reduce the risk of knitting a defective double knit fabric.

[0064] According to this method, a feeder (first feeder 20 or second feeder 30) guides a knitting yarn by one of a yarn feeder on one side, a guide groove, or a yarn feeder on the other side. The knitting yarn is guided by a guide member (guide member 23A, guide member 23B, or guide member 33B) attached to the feeder. As a result, the space for arranging the yarn path for the knitting yarn guided by the feeder can be expanded. This further reduces the risk of the direction of extension of the yarn path for the knitting yarn guided by the feeder being reversed.

[0065] According to this method, the yarn path arrangement space for the knitting yarn guided by the feeder (first feeder 20 or second feeder 30) is expanded upstream as viewed in the direction of rotation of the cylinder in the circular knitting machine 40. As a result, the direction in which the yarn path for the knitting yarn extends from the guide member (guide member 23A, guide member 23B, or guide member 33B) to the feeder is aligned with the direction in which the yarn path for the knitting yarn extends from the feeder to the knit region. This reduces damage to the knitting yarn caused by rubbing against the feeder.

[0066] Next, a method for producing a double knit fabric according to a second embodiment (hereinafter, simply referred to as the "method" in the description of the second embodiment) will be described. This method uses the circular knitting machine 40 used in the method for producing a double knit fabric according to the first embodiment, but changes the application of a feeder to the circular knitting machine 40 and the knitting mode of the knitting yarn.

[0067] This method also utilizes the feeders used in the method for producing a double knit fabric according to the first embodiment. That is, a set of four feeders, the first feeder 20, the second feeder 30, and the feeders 40A and 40B, is considered as one set, and an appropriate number of these sets are applied to the circular knitting machine 40. In the second embodiment, the feeders are periodically arranged in the order of feeder 40B, second feeder 30, first feeder 20, feeder 40A, feeder 40B, etc., as viewed in the direction of rotation of the cylinder of the circular knitting machine 40.

[0068] In this method, a double knit fabric is produced by carrying out knitting steps according to the knitting diagrams shown as F1 to F4 in Fig. 10 on an interlocking circular knitting machine 40 to which the above-mentioned feeders are applied. These knitting diagrams represent knitting steps similar to those for a type of double knit fabric called "ponchideroma."

[0069] In Fig. 10, F1 is a knitting diagram showing the knitting setting (skipping one stitch) for the knitting yarn passed through feeder 40A. F2 is a knitting diagram showing the knitting setting (skipping one stitch rib knitting set in the part skipped by the rib knitting of F1) for the knitting yarn passed through feeder 40B. These knitting yarns constitute the structure of the connecting yarn in the produced double knit fabric. Note that an appropriately selected spun yarn or filament yarn can be used as the knitting yarn passed through feeders 40A and 40B. In the second embodiment, the same type of yarn is used as the knitting yarn passed through feeders 40A and 40B.

[0070] F3 is a knitting diagram showing the knitting setting (bare jersey knitting with dial needle 42B) for the knitting yarn guided by the second feeder 30. Here, the "knitting yarn guided by the second feeder 30" refers to two knitting yarns: one passed through the other-side yarn feeder 32A of the second feeder 30 shown in FIG. 6 and guided, and the other passed through the guide groove 30A and guided. These knitting yarns are guided in an aligned state in the knit region of the dial needle 42B, which is positioned immediately below the second feeder 30 on the downstream side in the cylinder rotation direction of the circular knitting machine 40. In this knit region, the knitting yarn guided from the other-side yarn feeder 32A constitutes the other-side ground knit structure of the double knit fabric to be produced. In addition, in the knit region, the knitting yarn guided from the guide groove 30A shown in FIG. 2 constitutes the other-side plating structure of the double knit fabric to be produced. In the second embodiment, the knitting yarn for forming the ground knitting structure on the other side is the same type of yarn as the knitting yarn passed through feeders 40A and 40B, and the knitting yarn for forming the plating structure on the other side is a filament yarn having polyurethane filaments.

[0071] F4 is a knitting diagram showing the knitting setting (bare jersey knitting with cylinder needles 41B) for the knitting yarn guided by the first feeder 20. Here, the "knitting yarn guided by the first feeder 20" refers to two knitting yarns: one knitting yarn passed through one side yarn feeder 21A of the first feeder 20 shown in FIG. 3 and guided therethrough, and the other knitting yarn passed through the guide groove 20A and guided therethrough. These knitting yarns are guided in an aligned state in the knit region of the cylinder needle 41B shown in FIG. 2, which is positioned immediately below the first feeder 20 on the downstream side in the cylinder rotation direction of the circular knitting machine 40. In this knit region, the knitting yarn guided from one side yarn feeder 21A shown in FIG. 3 constitutes one side ground knit structure in the double knit fabric to be produced. In addition, in the knit region, the knitting yarn guided from the guide groove 20A constitutes one side plating structure in the double knit fabric to be produced. In the second embodiment, the knitting yarn for forming the ground knitting structure on one side is the same type of yarn as the knitting yarn passed through feeders 40A and 40B. Also, the knitting yarn for forming the plating structure on one side is the same type of filament yarn as the knitting yarn for forming the plating structure on the other side.

[0072] According to the method of the second embodiment, it is possible to enjoy the same effects as those described above as the method of producing a double knit fabric according to the first embodiment.

[0073] According to the method of the second embodiment, the circular knitting machine 40 can knit a double knit fabric having a five-layer structure as a whole by a knitting process similar to that of a ponchederoma. This makes it possible to produce a double knit fabric having a five-layer structure as a whole and having the advantages of a ponchederoma (such as being relatively resistant to stretching and drooping as a knitted fabric).

[0074] The above has described the embodiments of the present disclosure using the first and second embodiments. However, it will be apparent to those skilled in the art that various substitutions, modifications, and alterations are possible without departing from the scope of the present disclosure. In other words, the embodiments of the present disclosure may include all substitutions, modifications, and alterations that do not depart from the spirit and purpose of the claims appended hereto. For example, the following various embodiments can be implemented as embodiments of the present disclosure.

[0075] (1) In the method for producing a double knit fabric according to the first or second embodiment, two types of feeders are applied to a circular knitting machine: a feeder according to the present disclosure and a feeder capable of setting only one yarn path for the knitting yarn. The feeder capable of setting only one yarn path for the knitting yarn is passed through with a knitting yarn for forming the connecting yarn structure of the double knit fabric. However, the method for producing a double knit fabric according to the present disclosure may also be performed by applying only the feeder according to the present disclosure to a circular knitting machine. In this case, the knitting yarn for forming the connecting yarn structure can be guided to the knitting yarn region by passing it through either one yarn feeder or the other yarn feeder of the feeder.

[0076] (2) The feeder according to the first embodiment is equipped with a guide member that further guides the knitting yarn guided by one of the yarn feeders, the guide groove, or the other yarn feeder of the feeder. However, the feeder according to the present disclosure may not be equipped with such a guide member. Furthermore, the feeder according to the present disclosure may be equipped with a guide member that further guides the knitting yarn guided by another feeder used in the same circular knitting machine. In this case, the yarn path arrangement space for the knitting yarn guided by the other feeder can be expanded beyond the arrangement space allocated to the other feeder, further reducing the risk of the direction of extension of the knitting yarn path being reversed.

[0077] (3) In the feeder according to the present disclosure, the guide groove is not limited to being provided at the base portion where the protruding piece protrudes from the main body, but may be provided at a position closer to the tip end of the protruding piece from the base portion. In this case, the protruding piece constitutes at least a part of the wall of the guide groove.

Claims

1. A double knit fabric having a structure in which one side knitted fabric constituting one surface and another side knitted fabric constituting the other surface are connected together by a connecting yarn, the one side knitted fabric having a one side ground knit structure exposed to the one side and a one side plating structure aligned along the other side surface of the one side ground knit structure, the other side knitted fabric having a other side ground knit structure exposed to the other side and an other side plating structure aligned along the one side surface of the other side ground knit structure, the feeder being applied to a dial-cylinder type circular knitting machine which is a device for producing the double knit fabric, the feeder comprising: a main body set at a position radially outward of the dial from the needle bed of the cylinder of the circular knitting machine; a one-side yarn feeder that is opened on a surface of the main body that is radially inward of the dial, and that guides the knitting yarn to be knitted as the one-side ground knit structure toward the knit area of ​​a cylinder needle set on the needle bed of the cylinder when the knitting yarn is passed through from the radially outward; a guide groove that guides the knitting yarn to be knitted as the other-side plating structure or the one-side plating structure toward the knit area of ​​a dial needle set on the needle bed of the dial or the knit area of ​​the cylinder needle; a protruding piece that protrudes radially outward from the main body and forms at least a part of a wall of the guide groove; and a other-side yarn feeder that is provided on the protruding piece and that guides the knitting yarn to be knitted as the other-side ground knit structure toward the knit area of ​​the dial needle when the knitting yarn is passed through.

2. A feeder as described in claim 1, wherein the protruding piece covers a dial needle outlet area, which is an area in the circular knitting machine where the dial needle is extended radially outward to receive the knitting yarn, from the side where the dial needle receives the knitting yarn, and the other side yarn feed port is opened on the end face of the protruding piece that faces the dial needle outlet area.

3. A feeder as described in claim 2, wherein the other side yarn feed port is inclined radially inwardly toward the dial needle outlet area.

4. A feeder as claimed in claim 3, wherein the other side yarn feeder extends at a first inclination angle relative to the needle bed of the dial, and the one side yarn feeder is inclined radially inward towards the needle bed of the dial and extends at a second inclination angle smaller than the first inclination angle relative to the needle bed of the dial.

5. A feeder as described in claim 4, wherein the guide groove is inclined radially inward toward the needle bed of the dial and extends at a third inclination angle relative to the needle bed of the dial that is smaller than the first inclination angle and larger than the second inclination angle.

6. A feeder according to any one of claims 1 to 5, wherein the guide groove is located between the one-side yarn feeder opening and the other-side yarn feeder opening, and the guide groove, the one-side yarn feeder opening, and the other-side yarn feeder opening are spaced apart from each other.

7. A method for producing a double knit fabric, in which a one-side knit fabric constituting a surface on one side and a other-side knit fabric constituting a surface on the other side are joined together by a connecting yarn, the one-side knit fabric having a one-side ground knit structure exposed to the one side and a one-side plating structure aligned along the other-side surface of the one-side ground knit structure, the other-side knit fabric having a other-side ground knit structure exposed to the other side and a other-side plating structure aligned along the one-side surface of the other-side ground knit structure, by a dial-cylinder type circular knitting machine, the method comprising the steps of: applying a first feeder and a second feeder, each of which is a feeder as set forth in any one of claims 1 to 6, to the circular knitting machine; and passing a knitting yarn to be knitted as the one-side ground knit structure through the one-side yarn feeder of the first feeder from the radially outer side; A method for producing a double knit fabric, comprising the steps of: hanging a knitting yarn to be knitted in the one side plating structure in the guide groove of the first feeder; hanging a knitting yarn to be knitted in the other side plating structure in the guide groove of the second feeder; and passing a knitting yarn to be knitted in the other side ground knit structure through the other side yarn feeder; and knitting these knitting yarns by the circular knitting machine to produce the double knit fabric.

8. A method for producing a double knit fabric as described in claim 7, comprising the steps of: attaching a guide member for guiding the knitting yarn to the feeder; and carrying out the knitting step while the knitting yarn guided by the guide member is further guided by either the one-side yarn feed port, the guide groove, or the other-side yarn feed port of the feeder.

9. A method for producing a double knit fabric as described in claim 8, comprising carrying out the knitting step with the guide member disposed upstream of the feeder as viewed in the direction of rotation of the cylinder of the circular knitting machine.

10. A method for producing a double knit fabric as claimed in claim 7, comprising the steps of: applying a third feeder and a fourth feeder to the circular knitting machine; and carrying out the knitting step while a knitting yarn for forming the structure of the connecting yarn is passed through each of the third feeder and the fourth feeder.

11. A method for producing a double knit fabric according to claim 10, comprising: applying a feeder set including the first feeder, the second feeder, the third feeder, and the fourth feeder to the circular knitting machine; and carrying out the knitting step with the circular knitting machine adjusted to have an interlocking encounter; and with the knitting settings F1 to F6 below set. F1: knitting setting for the connecting yarn passed through the third feeder. F2: knitting a plain stitch knit with the cylinder needle for the knitting yarn passed through one of the yarn feed ports of the first feeder. F3: knitting a plain stitch knit with the dial needle for the knitting yarn passed through the other yarn feed port of the second feeder. F4: knitting setting for the connecting yarn passed through the fourth feeder. F5: knitting a plain stitch knit with the cylinder needle for the knitting yarn hung in the guide groove of the first feeder. F6: Setting of plain stitch knitting by the dial needle for the knitting yarn hung on the guide groove of the second feeder.

12. A method for producing a double knit fabric as claimed in claim 10, comprising carrying out the knitting step with the circular knitting machine adjusted to have an interlocking encounter and with the knitting settings F1 to F4 below set. F1: Knit setting for the connector yarn passed through the third feeder. F2: Setting of knitting of the connecting yarn passed through the fourth feeder. F3: Setting of bare jersey knitting by the dial needle for the knitting yarn passed through the other side yarn feeder of the second feeder and the knitting yarn hung on the guide groove of the second feeder. F4: Setting of bare jersey knitting by the cylinder needle for the knitting yarn passed through the one side yarn feeder of the first feeder and the knitting yarn hung on the guide groove of the first feeder.

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