Circular Weft Knitting for Terrycloth-Float Motif Combinations
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Solution Overview
Problem
Existing circular knitting machines for seamless knitwear production are limited in the combinations of knitted fabric structures they can produce, resulting in unsatisfactory aesthetic and technical characteristics, lack versatility, and cannot effectively create complex patterns and motifs.
Innovation Solution
A process for manufacturing textile items using a circular weft knitting machine that allows for the combination of terrycloth and floated knitted fabric on successive rows, enabling selective needle-sinker interactions to create alternating sequences of different knitted structures, including terrycloth, floated, and plain fabrics, with optional color variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional circular knitting machines are used with standard processing techniques, then production is simple and economical, but the combinations of knitted fabric structures are limited and aesthetic quality is unsatisfactory
Solution Approach 1:
The knitting process is segmented into distinct phases (unloaded needle phase for terrycloth formation, withdrawn needle phase for float creation) that can be selectively applied to different needle groups. This segmentation allows multiple fabric structures to be combined within a single knitting cycle without requiring complex machine modifications.
Solution Approach 2:
The patent implements dynamic control of needle states through programmable needle selection, where needles can be dynamically assigned to different operational modes (unloaded, withdrawn, or standard) based on the desired fabric pattern. This dynamic reconfiguration enables versatile fabric combinations while maintaining a relatively simple machine structure.
2Manufacturing precision
If limited processing techniques are used on circular knitting machines, then device complexity remains low, but the aesthetic characteristics and patterns obtainable are limited
Solution Approach 1:
Different fabric structures (terrycloth, float, plain) are applied to different local zones or needle groups within the same knitting cycle. This local differentiation allows complex patterns and aesthetic variations across the fabric surface while using standard machine components, avoiding the need for complex overall system redesign.
Solution Approach 2:
The patent employs preliminary needle selection and programming before the knitting cycle begins, where the desired pattern and fabric structure distribution are pre-planned. This preliminary action enables complex aesthetic outcomes through simple execution, as the machine follows pre-determined instructions rather than requiring complex real-time control.
3Adaptability or versatility
If standard knitting processes are used, then production is economically competitive, but versatility in fabric structure combinations is insufficient
Solution Approach 1:
The knitting process maintains continuous production by integrating multiple fabric structure formations within a single uninterrupted knitting cycle. The unloaded needle and withdrawn needle techniques are incorporated into the standard cycle flow without requiring stopping or additional processing steps, thus maintaining productivity while enhancing versatility.
Solution Approach 2:
The patent makes the standard circular knitting machine multi-functional by enabling it to produce multiple fabric structures (terrycloth, float, plain, and their combinations) using the same basic machine components and single knitting cycle. This universality allows one machine to replace multiple specialized machines, maintaining economic competitiveness while achieving high versatility.
Data Source
AI summary
A process for manufacturing a textile item by means of a circular weft knitting machine, of seamless type and provided at least with a feed, a needle-bearing organ supporting a plurality of needles, and a plurality of knockover sinkers provides the programming of the knitting machine so as to define a textile item consisting of a plurality of successive stitch rows of knitted fabric in succession, and to produce weft knitted fabric for manufacturing the textile item, according to the programming step. In the programming step is set at least a designed motif, defined on at least two successive stitch rows, i.e. following one another, in which: in at least one of the two successive rows a portion of terrycloth knitted fabric is present; in at one of the two successive rows a portion of floated knitted fabric is present.