Double-Sided Fabric Thickness via Loop Presser Bed Stacking
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Solution Overview
Problem
Current flat bed knitting machines are limited in embedding continuous cord materials longer than 1 inch due to inclined angles, resulting in unsatisfactory fabric production, restricting the thickness and pattern variations of double-sided fabrics.
Innovation Solution
A flat bed knitting machine with a loop presser bed and staggered needle beds is used to guide and feed continuous cord material between the front and back needle beds, allowing it to be stacked and folded within the knitted sack, creating a double-sided fabric with varying thicknesses and relief embossing, eliminating the need for additional filler materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If continuous cord material longer than 1 inch is fed by yarn feeder with inclined angle, then fabric thickness and pattern variations can be increased, but the continuous cord material cannot be reliably knitted by knitting needle resulting in unsatisfactory fabric
Solution Approach 1:
The patent introduces a loop presser bed with pressing pieces as an intermediary mechanism between the yarn feeder and knitting needles. The pressing pieces press the continuous cord material against the knitting needles, ensuring reliable knitting of long cord materials that would otherwise be unreliable due to inclined angle feeding issues
Solution Approach 2:
The loop presser bed is divided into multiple pressing pieces that can independently press different sections of the continuous cord material. This segmentation allows each pressing piece to work on specific cord material sections, improving overall knitting reliability while enabling fabric thickness variation through different pressing configurations
2Ease of manufacture
If continuous cord material is embedded using conventional yarn knitted operations, then fabric production is possible, but the length of continuous cord material cannot exceed 1 inch restricting fabric design
Solution Approach 1:
The loop presser bed is designed to move dynamically with the knitting process, and the pressing pieces can be selectively activated or deactivated. This dynamic control allows the system to adapt to different cord material lengths and fabric design requirements, greatly enhancing versatility while maintaining ease of manufacture
Solution Approach 2:
The loop presser bed serves multiple functions: it presses continuous cord material for reliable knitting, enables variation of fabric thickness, and allows different fabric pattern designs. This multi-functionality makes the knitting machine universally applicable to various fabric production needs without limiting cord material length
3Ease of operation
If additional filler materials are used to achieve thickness and piling effects, then fabric comfort and design requirements can be satisfied, but manpower and time costs increase due to post-processing
Solution Approach 1:
The loop presser bed performs the thickness creation action during the knitting process itself, rather than requiring post-processing filler materials. The pressing pieces pre-compress the continuous cord material to create the desired thickness and piling effects directly in the fabric structure, eliminating subsequent processing steps and reducing production time
Solution Approach 2:
The continuous cord material serves its own purpose of creating fabric thickness and piling effects through the pressing action, eliminating the need for separate filler materials. The system uses the cord material itself to achieve the desired fabric properties, reducing complexity and production time while maintaining high-quality comfort and design characteristics
Data Source
AI summary
A double-sided fabric stacked with a continuous cord material and forming a thickness in a knitted sack is knitted from a face yarn by a flat knitting machine including a front needle bed, a back needle bed and a loop presser bed. The front needle bed includes a plurality of front knitting needles. The back needle bed includes a plurality of back knitting needles. The loop presser bed is disposed above the front or back needle bed, and includes right-directed and left-directed knitting pressing pieces. The double-sided fabric further includes at least one knitted sack including loops knitted from the face yarn by the front and back knitting needles. The knitted sack includes therein at least one continuous cord material, which is pressed into the knitted sack by the right-directed and left-directed knitting pressing pieces to become folded and stacked to form a thickness.