Double Raschel Warp Knitting Machine Patterned Irregularities
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Solution Overview
Problem
Conventional warp knitting machines struggle to create significant irregularities conforming to patterns in warp knitted fabrics, limiting their application in manufacturing methods like shoe uppers, where both pattern formation and structural irregularities are required.
Innovation Solution
A double raschel warp knitting machine is enhanced by inserting yarns between the front and back base fabrics and compressing them at specific points to form irregularities, allowing for the creation of concave and convex portions that match the jacquard pattern, thereby forming irregularities that are recognizable and functional.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional double raschel machine is used to manufacture warp knitted fabric, then the fabric can be produced with basic pattern formation, but the surface remains almost flat and cannot form significant irregularities conforming to the pattern
Solution Approach 1:
The knitting process is segmented into front-side knitting and back-side knitting operations. The front-side row of knitting needles forms the front-side base fabric with pattern, while the back-side row of knitting needles forms the back-side base fabric. By coordinating these segmented knitting operations, irregularities conforming to the pattern are formed on the front-side surface while maintaining a relatively simple machine structure.
Solution Approach 2:
The invention utilizes the front-back dimensional relationship by knitting the front-side base fabric and back-side base fabric separately on opposite sides of the machine. The front-side fabric is formed with pattern and irregularities, while the back-side fabric provides structural support. This dimensional approach enables surface irregularity formation without significantly complicating the machine structure.
2Shape
If quilting manufacturing method is used to create irregularities, then cloth with irregularities can be produced, but the manufacturing process becomes complicated requiring separate front and back cloth production, core material insertion, and sewing
Solution Approach 1:
The invention merges the irregularity formation process with the base fabric knitting process. Both the front-side base fabric and back-side base fabric are knitted simultaneously in a single continuous operation on the double raschel machine, with irregularities formed during knitting rather than through separate quilting steps. This eliminates the need for separate core material insertion and sewing operations.
Solution Approach 2:
The knitting process operates continuously to form both the front-side and back-side base fabrics along with the irregularities in a single uninterrupted operation. The front-side row and back-side row of knitting needles work continuously and coordinately, eliminating the discontinuous steps of separate fabric production, assembly, and sewing required in traditional quilting methods.
3Shape
If thicker yarns are supplied to 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 invention applies different knitting characteristics to different locations: the front-side row of knitting needles knits the front-side base fabric with pattern formation and irregularity creation, while the back-side row knits the back-side base fabric with different stitch patterns. This local differentiation enables the formation of irregularities with sufficient size to be recognized at a glance while maintaining precise pattern conformity through coordinated control of both knitting rows.
Data Source
Figure 1
Figure 2(a)~2(f)
Figure 3(a)~3(e)
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).