Knitting Blister Fabric Yarns on Dial to Stop Shining-Through
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Solution Overview
Problem
Double jersey knit fabrics with large designs experience issues such as 'shining-through' of yarns, loop formation, and quality loss due to floating yarns between the front and back of the fabric, especially when using smooth filament yarns, leading to a less soft and less aesthetically pleasing fabric.
Innovation Solution
The method involves knitting or tucking all yarns forming the blister fabric on the back of the fabric using the dial's needles, ensuring these yarns are always behind the lay-in yarns and securely connected, thereby reducing the 'shining-through' effect and preventing loop formation, while maintaining the connection between the front and back layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If yarns are used for knitting blister fabric on the cylinder and allowed to float over long distances, then the fabric can maintain a soft feeling in the design area, but the yarns become visible through the other color in the front of the fabric causing a 'shining-through' effect
Solution Approach 1:
The patent applies dimensionality change by moving the knitting action from the cylinder (front side) to the dial (back side). The yarns that would normally float in front are instead knitted on the back of the fabric, effectively moving the problem from one spatial dimension (front) to another (back), thereby eliminating the visible shining-through effect while preserving the soft feel.
Solution Approach 2:
The dial acts as an intermediary mechanism that captures and secures the floating yarns from the cylinder. By introducing this intermediate knitting layer on the back side, the patent prevents the direct visibility of floating yarns through the fabric front, mediating between the soft feel requirement and the aesthetic appearance requirement.
2Strength
If yarns are knitted on both the cylinder and the dial to connect front and back, then the fabric structure is strengthened, but the yarns are not smooth and small loops can be formed which can be easily pulled out
Solution Approach 1:
The patent extracts the problematic knitting action from the cylinder and relocates it to the dial. By taking out the yarn manipulation from the front-side cylinder and performing it on the back-side dial, the patent eliminates the formation of pullable loops while maintaining the connecting function between front and back fabric layers.
Solution Approach 2:
Instead of knitting the connecting yarns on the cylinder as in conventional methods, the patent inverts the approach by knitting them on the dial. This inversion of the knitting location and sequence prevents the formation of defective loops while still achieving the structural connection between fabric layers.
3Ease of operation
If the front of the fabric comprises areas of blister fabric with floating yarns, then the fabric feels soft in the design area, but the two adjacent blister fabrics of the front and back can be easily pulled open
Solution Approach 1:
The patent merges the functions of creating soft feel and maintaining fabric integrity into a single coordinated action on the dial. By combining the knitting of design yarns and structure-stabilizing yarns on the back side, the patent achieves both softness in the design area and prevention of blister fabric separation without compromising either property.
Data Source
Figure 1~2
AI summary
The invention relates to a method for knitting a double jersey knit fabric (11) on a double jacquard, double jersey circular knitting machine, the double jersey knit fabric (11) having a design consisting of more than 12 needles, wherein the knitting machine comprises a cylinder (C) and a dial (D) provided with needles each separately driven by an electronical pattern controlling mechanism, wherein the needles of the cylinder (C) are provided for knitting the front (F) of the fabric (11), and the needles of the dial (D) are provided for knitting the back (B) of the fabric, and wherein the front (F) of the fabric (11) comprises at least one area of blister fabric (5), wherein a non-reversible single-sided designed knit fabric (11) is knitted having a desired design at the front of the fabric (11) and a technical design at the back of the fabric (11), wherein this technical design is created by knitting or tucking one or more of the yarns (7, 8, 9 and/or 10) that are used for forming the blister fabric (6) with at least one stitch (3) or tuck solely on the needles of the dial (D), missing at least one needle on the dial (D) before and/or after this at least one stitch (3) or tuck in the areas (16) where the one or more yarns (7, 8, 9 and/or 10) are not knitting or tucking the design in the front (F) of the fabric (11) on the needles of the cylinder (C). The invention further relates to a double jersey knit fabric (11) knitted by such a method.