Flat Knitting Machine Integral 3D Fabric Structure
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Solution Overview
Problem
Conventional weft-knitted fabrics cannot be knitted integrally to form a three-dimensional structure, requiring separate knitting and subsequent processing, which leads to discomfort due to spliced edges and potential skin and environmental issues from chemical adhesives.
Innovation Solution
A method using a flat knitting machine to knit a basic structure and a three-dimensional structure with varying thickness, where the three-dimensional structure has two surface layers and a supporting portion, eliminating the need for post-processing and allowing adjustable thickness and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If three-dimensional fabric and general knitted fabric are knitted separately and combined by sewing or chemical adhesives, then the three-dimensional structure can be formed, but spliced edges are created which greatly reduce comfort and chemical adhesives may affect skin and environment
Solution Approach 1:
The patent combines the knitting of three-dimensional structure and general knitted fabric into a single integral knitting process. The flat knitting machine knits both structures continuously without separation, eliminating the need for subsequent sewing or chemical adhesive bonding. This merging of processes eliminates spliced edges and avoids chemical adhesive harm while maintaining the desired three-dimensional shape.
Solution Approach 2:
The patent performs the knitting of both the three-dimensional structure and general knitted fabric in advance as a single integrated process. By planning and executing the knitting sequence to include both structures from the beginning, the patent avoids the need for post-processing steps like sewing or adhesive application, thereby eliminating the harmful effects associated with these subsequent operations.
2Shape
If three-dimensional fabric is knitted independently and then combined with general knitted fabric by sewing, then the three-dimensional structure is formed, but the process requires multiple steps and creates spliced edges
Solution Approach 1:
The patent merges the knitting operations for the three-dimensional structure and general knitted fabric into a single continuous process using one flat knitting machine. This integration eliminates the need for separate knitting operations and subsequent joining steps such as sewing or adhesive application, thereby reducing process complexity while maintaining the three-dimensional structure.
Solution Approach 2:
The patent performs both the three-dimensional structure knitting and general knitted fabric knitting in advance as a single integrated operation. By planning the knitting sequence to produce both structures simultaneously, the patent eliminates the need for multiple sequential processing steps, thereby simplifying the overall manufacturing process.
3Stability of the object's composition
If chemical adhesives are used to combine fabrics, then the three-dimensional structure can be attached, but the adhesives may undergo qualitative changes and affect the wearer's skin and environment
Solution Approach 1:
The patent combines the fabrication and attachment processes into a single knitting operation. By knitting both the three-dimensional structure and general knitted fabric together in one process, the patent eliminates the need for chemical adhesives entirely, thereby removing the harmful effects on skin and environment while maintaining stable fabric attachment through the knitted structure itself.
Solution Approach 2:
The patent converts the potential harm of chemical adhesives into a beneficial knitting structure. Instead of relying on chemical adhesives for attachment, the patent uses the knitting process to create an integral structural connection that provides both attachment and comfort, thereby transforming a harmful approach into a beneficial one.
4Shape
If the flat knitting machine knits the basic structure first and then the three-dimensional structure, then the fabric can be formed with varying thickness, but the supporting yarn must be temporarily suspended and re-fed
Solution Approach 1:
The patent performs the preliminary action of suspending the supporting yarn feed at the junction between the basic structure and three-dimensional structure, then re-feeds it after the surface layer portions are knitted. This preliminary planning of the yarn feeding sequence allows for the formation of varying thickness while managing the complexity of yarn control through pre-determined timing and positioning.
Data Source
AI summary
The invention provides a method for knitting and forming a weft-knitted fabric with varying thickness by a flat knitting machine and a weft-knitted fabric thereof. The method is implemented in at least one knitting process of the weft-knitted fabric, comprising steps of: driving the flat knitting machine to knit a basic structure by at least one of two needle beds of the flat knitting machine, and controlling the two needle beds on the flat knitting machine to knit a three-dimensional structure connected with the basic structure. A thickness of the three-dimensional structure is greater than a thickness of the basic structure, the three-dimensional structure comprises two surface layer portions and a supporting portion connected with the two surface layer portions and located between the two surface layer portions. A junction between the three-dimensional structure and the basic structure is without the supporting portion.