Flat Knitting Machine Integrating 3D Spacer Fabric
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Solution Overview
Problem
Existing methods for creating three-dimensional fabrics with varying thickness require separate knitting and subsequent sewing or adhesive bonding, which compromises comfort and can lead to stuffiness and environmental concerns due to chemical adhesives.
Innovation Solution
A method for knitting a weft-knitted fabric using a flat knitting machine that integrates both basic and three-dimensional structures, allowing for varying thickness without the need for post-knitting assembly, using a supporting yarn to form a bag-like structure that enhances thickness without splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If three-dimensional fabric and general knitted fabric are knitted separately and combined by sewing and splicing, then the fabric can achieve varying thickness, but spliced edges are formed that reduce comfort
Solution Approach 1:
The patent merges the knitting of three-dimensional fabric and general knitted fabric into a single integrated knitting process using a flat knitting machine with two needle beds. The first needle bed knits the basic structure while the second needle bed knits the three-dimensional structure with varying thickness, eliminating the need for separate knitting and subsequent splicing operations.
Solution Approach 2:
The patent segments the knitting process into two simultaneous operations on different needle beds: the first needle bed produces the basic knitted fabric while the second needle bed produces the three-dimensional spacer structure. This segmentation allows both fabric types to be created in parallel and integrated without splicing.
2Shape
If chemical adhesives are used to combine three-dimensional fabric and general knitted fabric, then the fabric can achieve varying thickness, but the adhesives may affect wearer's skin and environment
Solution Approach 1:
The patent extracts and eliminates the use of chemical adhesives from the fabric construction process. Instead of using adhesives to bond the three-dimensional fabric to the general knitted fabric, the invention uses mechanical interlocking through spacer strands that physically connect the two surfaces without requiring any chemical bonding agents.
Solution Approach 2:
The patent introduces spacer strands as intermediary elements that mechanically connect the first surface (basic knitted fabric) and the second surface (three-dimensional structure). These spacer strands act as mediators that provide structural connection and varying thickness without requiring chemical adhesives, thereby eliminating skin irritation and environmental concerns associated with adhesive chemicals.
3Shape
If separate knitting and assembly processes are used, then the fabric can achieve varying thickness, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple manufacturing operations (knitting of basic fabric, knitting of three-dimensional structure, and assembly) into a single integrated knitting process. The flat knitting machine with two needle beds simultaneously produces both fabric types and integrates them in one continuous operation, eliminating the need for separate assembly steps.
Solution Approach 2:
The patent performs preliminary actions by pre-configuring the flat knitting machine with two needle beds positioned at specific distances apart, which determines the thickness of the final fabric. The spacer strands are also prepared in advance with predetermined lengths that correspond to the desired thickness variations, allowing the varying thickness structure to be formed automatically during the knitting process without complex post-processing.
4Shape
If needle beds are spaced relative to one another, then a spacer knit construction can be formed, but multiple spacer strands are needed to provide support capability
Solution Approach 1:
The patent makes the spacer strands multi-functional by designing them to simultaneously perform multiple roles: (1) connect the first surface and second surface, (2) provide mechanical support between the needle beds, (3) determine the thickness of the fabric, and (4) enable the spacer knit construction. This universality allows a single spacer strand to fulfill multiple functions that would otherwise require separate components.
Data Source
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AI summary
The invention provides a method (20) for knitting and forming a weft-knitted fabric (10) with varying thickness by a flat knitting machine (30) and a weft-knitted fabric (10) thereof. The method (20) is implemented in at least one knitting process of the weft-knitted fabric (10), comprising steps of: driving the flat knitting machine (30) to knit a basic structure (11) by at least one of two needle beds (31, 32) of the flat knitting machine (30), and controlling the two needle beds (31, 32) on the flat knitting machine (30) to knit a three-dimensional structure (12) connected with the basic structure (11). A thickness of the three-dimensional structure (12) is greater than a thickness of the basic structure (11), the three-dimensional structure (12) comprises two surface layer portions (121, 122) and a supporting portion (123) connected with the two surface layer portions and located between the two surface layer portions (121, 122). Ajunction (13) between the three-dimensional structure (12) and the basic structure (11) is without the supporting portion (123).