Double Raschel Warp Knitting Machine Irregularity Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional warp knitting machines struggle to form significant irregularities conforming to patterns in warp knitted fabrics, limiting their application in manufacturing methods like shoe uppers, where both pattern and texture are required.
Innovation Solution
A double raschel machine with additional guide bars between jacquard bars at the front and back sides, allowing for the insertion and compression of insertion yarns between base fabrics to create jacquard patterns with noticeable irregularities, enabling the formation of convex and concave portions that match the pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional double raschel machine with front and back jacquard bars is used, then a jacquard pattern can be formed on the warp knitted fabric, but the surface remains almost flat and only slight irregularities recognizable by touch can be formed
Solution Approach 1:
The patent introduces a new spatial dimension by adding guide bars positioned between the front and back jacquard bars. This intermediate positioning allows insertion yarns to be introduced from a new dimension, creating pronounced three-dimensional irregularities that extend beyond the traditional two-dimensional jacquard pattern formation. The insertion yarns create convex portions that protrude from the fabric surface, adding vertical dimensionality to the pattern.
Solution Approach 2:
The patent uses insertion yarns as intermediary elements that are introduced through guide bars positioned between the front and back jacquard bars. These insertion yarns act as mediators that create the irregularities by being compressed between the front and back base fabrics at joining positions. The intermediary guide bars enable the insertion yarns to be positioned precisely where needed to create the desired surface irregularities without interfering with the primary jacquard pattern formation.
2Shape
If quilting is used to create irregularities, then cloth with significant irregularities can be obtained, but the manufacturing method becomes complicated requiring separate front and back cloth production, core material insertion, and sewing
Solution Approach 1:
The patent merges multiple functions into a single integrated knitting process. The double raschel machine simultaneously performs jacquard pattern formation, base fabric creation, and irregularity generation in one continuous operation. The insertion yarns are introduced and compressed during the same knitting cycle that forms the base fabrics, eliminating the need for separate quilting steps involving core material insertion and sewing. This combines what would traditionally be separate manufacturing operations into a unified process.
Solution Approach 2:
The knitting machine performs self-service by automatically creating the irregularities during the knitting process itself. The insertion yarns are introduced through the guide bars and automatically compressed between the front and back base fabrics at the joining positions formed by the jacquard mechanisms. This self-compression eliminates the need for external compression devices or manual quilting operations, allowing the fabric to generate its own irregularities through the knitting process.
3Shape
If thicker yarns are supplied to a jacquard bar to form irregularities, then slight irregularities recognizable by touch can be created, but irregularities with sufficient size to be recognized at a glance cannot be formed
Solution Approach 1:
The patent segments the irregularity formation function from the pattern formation function. The jacquard bars are dedicated to precise pattern formation using jacquard yarns, while separate insertion yarns introduced through intermediate guide bars are dedicated to creating irregularities. This segmentation allows each system to optimize for its specific function: the jacquard mechanism maintains precise pattern control while the insertion yarns create pronounced surface irregularities through compression at joining positions, without compromising either precision or irregularity size.
Data Source
AI summary
Provided is a warp knitting machine capable of irregularities conforming to a pattern in a warp knitted fabric.The warp knitting machine according to an embodiment is a double raschel machine, and includes at least one guide bar GB5 between a pair of jacquard bars at a front side (JB3, JB4), and a pair of jacquard bars at a back side (JB6, JB7).