Circular Knitted Garment Apertures via Reciprocating Direction
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Solution Overview
Problem
Circular knitting machines struggle to produce garments with open patterns, such as socks or sleeves, that require spaced openings for ventilation, thermoregulation, comfort, or aesthetic purposes, as previous methods necessitate modified equipment and cannot simultaneously knit terry stitches without modifications.
Innovation Solution
A method involving reciprocating circular knitting directions to create apertures in a circular knitted apparel item by reversing the knitting direction at desired locations, forming crossover strands between segments, allowing for the creation of multiple apertures without requiring modified needles or sinkers, enabling the knitting of various stitch configurations including terry stitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If transfer stitch is used to create open pattern, then ventilation and comfort are improved, but device complexity increases due to modified needles and sinkers
Solution Approach 1:
The knitting process is divided into multiple passes around the circular needle cylinder. In each pass, the needle cylinder is rotated in alternating directions (first direction, then second direction) to create segments of knitted fabric separated by apertures. This segmentation approach allows open patterns to be formed without modifying the knitting machine equipment.
Solution Approach 2:
The knitting operation employs periodic alternation of rotation directions. The needle cylinder rotates in a first direction for a certain number of courses, then reverses to rotate in a second direction for subsequent courses. This periodic reversal creates the aperture pattern while using the same standard knitting machine hardware throughout the process.
2Object-affected harmful factors
If transfer stitch is used to create open pattern, then comfort is improved, but manufacturing flexibility deteriorates as terry stitch cannot be knitted without modifications
Solution Approach 1:
The knitting machine's needle cylinder rotation direction is dynamically changed during the knitting process. The controller alternates the rotation direction between first and second directions based on the desired pattern. This dynamic adjustment allows the same machine to produce different stitch patterns (including terry stitch) and open patterns without physical modifications to the needles or sinkers.
Solution Approach 2:
The knitting process utilizes changes in the rotation direction parameter of the needle cylinder. By alternating between positive and negative rotation directions (first and second directions), the system creates different fabric structures. This parameter-based control enables versatility in stitch pattern production without hardware modifications.
3Ease of manufacture
If conventional circular knitting is used, then manufacturing simplicity is maintained, but open pattern creation is limited
Solution Approach 1:
The knitting process transitions from a single-direction circular path to a multi-directional approach. By introducing the second rotation direction opposite to the first direction, the system creates dimensional complexity in the knitting path, resulting in apertures and open patterns. This dimensional change in the knitting trajectory enables ventilation features while maintaining standard equipment.
Data Source
AI summary
Present aspects hereof are directed to a circular knitted garment, such as a sock, or a sleeve. The garment has at least a first segment with multiple knit courses, and a second segment having the same number of multiple knit courses as the first segment. The garment has an aperture separating the first segment and the second segment, where the aperture is occupied by a single strand of yarn extending from the first segment to the second segment. The first and second segments are formed by changing the circular knitting direction from one course to the next course in a reciprocating fashion, until the last course is formed, wherein the single strand of yarn moves from the last course in the current segment to the first course in a next, adjacent segment.