Knitted Fabric Vertical Yarn Integration
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Solution Overview
Problem
Incorporating vertical yarn filaments, such as electrically conductive yarns, into knitted fabrics to create smart textiles poses a challenge as they cannot be woven entirely non-visibly, requiring additional layers that increase weight and reduce wearing comfort.
Innovation Solution
A method using a flat knitting machine with multiple needle beds and yarn carriers to guide first and second yarns over the vertical yarn filament on the front and back sides of the fabric, securely fixing it without the need for additional knitting stitches, allowing for adjustable angles and visibility options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical yarn filaments are fastened on the knitted fabric at regular intervals by knitting stitches or tuck loops, then the vertical yarn filaments are securely fixed, but the vertical yarn filaments remain visible from the outside and require additional layers for coverage
Solution Approach 1:
The vertical yarn filament is nested between the front and back layers of the knitted fabric, with the first yarn forming loops on the front side and the second yarn forming loops on the back side that enclose the vertical yarn filament. This nesting approach secures the vertical yarn filament while completely concealing it within the fabric structure.
Solution Approach 2:
The solution moves from a single-layer approach to a multi-layer dimensional structure by introducing front and back yarn carriers that work simultaneously. The vertical yarn filament is positioned in the intermediate dimension between the front and back surfaces, allowing it to be secured without visibility.
2Shape
If a second layer is knitted to cover the vertical yarn filaments completely, then the vertical yarn filaments become non-visible from the outside, but the weight of the knitted fabric increases and wearing comfort is reduced
Solution Approach 1:
Instead of adding a complete second layer to cover the vertical yarn filaments, the invention uses partial action by incorporating the coverage function into the existing front and back yarn structures. The first and second yarns are guided to cover the vertical yarn filament at specific locations without requiring additional fabric layers.
3Adaptability or versatility
If vertical yarn filaments are incorporated into knitted fabrics, then smart textiles with integrated electrical components can be created, but the vertical yarn filaments cannot be woven entirely non-visibly without additional layers
Solution Approach 1:
The first and second yarns serve multiple functions: they form the basic knit structure, secure the vertical yarn filament through loop formation, and simultaneously cover the vertical yarn filament on the front and back sides. This multi-functionality integrates the smart textile capability without increasing structural complexity.
Data Source
AI summary
A method for manufacturing a knitted fabric embodying a basic knit, into which at least one functional yarn filament, such as an electrically conductive yarn filament, is incorporated as a vertical yarn filament (F3). The basic knit is formed from a first and a second yarn (F1, F2) using a plaiting technique. The vertical yarn filament (F3) is incorporated by a third yarn carrier (FF3) positioned, on a third yarn carrier rail located between respective yarn carrier rails for the first and the second yarn carriers (FF1, FF2), at a location at which the vertical yarn filament (F3) is to be incorporated. During formation of a sequence of stitch rows (MR1-MR7) using the first and second yarns (F1, F2), the first yarn (F1) is guided over the vertical yarn filament (F3) on a front side of the knitted fabric and the second yarn (F2) is guided over the vertical yarn filament (F3) on a back side of the knitted fabric.