Flat Bed Knitting Loop Presser for Curved Linear Material Embedding
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Solution Overview
Problem
Current flat bed knitting machines are limited in embedding continuous linear materials longer than 2.54 cm due to inclined angles, resulting in unsatisfactory fabric production, and existing methods cannot form double-sided fabrics with curved patterns or incorporate conductive yarns effectively.
Innovation Solution
A method using a flat bed knitting machine with a loop presser bed and staggered needles to embed continuous linear materials, forming loop groups that create curved patterns and allowing for the integration of conductive yarns into double-sided fabrics, enabling longer material lengths and varied patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional yarn knitting operations using a knitting needle are used to embed continuous linear material, then the embedding process can be performed, but the continuous linear material cannot be reliably knitted when its length exceeds 2.54 cm due to inclined angle issues
Solution Approach 1:
The patent introduces a pressing element as an intermediary component between the yarn feeder and the knitting needle. This pressing element presses the continuous linear material against the knitting needle during the embedding process, ensuring reliable engagement and knitting even when the material length exceeds 2.54 cm. The pressing element acts as a mediator that transfers and stabilizes the material positioning, eliminating the inclined angle problem that caused unreliable embedding in conventional methods.
2Adaptability or versatility
If existing knitting methods are used, then single-sided fabric can be manufactured, but double-sided fabric with curved patterns cannot be formed
Solution Approach 1:
The patent employs dynamic control of the pressing element's position and timing during the knitting cycle. By dynamically adjusting when and where the pressing element engages the continuous linear material, the system can create curved patterns on double-sided fabric while maintaining a relatively simple knitting process. The dynamic positioning allows the material to be embedded at varying angles and positions, enabling pattern formation without complex mechanical reconfiguration.
Solution Approach 2:
The patent divides the embedding process into distinct phases: material feeding, pressing against the knitting needle, and knitting. This segmentation allows each phase to be optimized independently, enabling the formation of complex curved patterns on double-sided fabric while keeping the overall process manageable. The continuous linear material is also effectively segmented into discrete embedding points along its length, allowing precise control over pattern formation.
3Quantity of substance
If conventional embedding processes are used, then basic fabric can be produced, but thicker and denser fabric with pattern changes and piling effects cannot be achieved
Solution Approach 1:
The patent maintains continuous action of the yarn feeder and pressing element throughout the knitting process, allowing continuous linear material to be consistently embedded at regular intervals. This continuous embedding process builds up thicker and denser fabric with each pass, creating piling effects and pattern variations without requiring intermittent stopping or complex reconfiguration of the knitting machine.
Data Source
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AI summary
A double-sided fabric embedded with a continuous linear material and formed as a curved form is provided. The double-sided fabric is woven by a flat bed knitting machine including a front needle bed including front knitting needles, a back needle bed including back knitting needles and a loop presser bed including right-directed and left-directed weaving pressing pieces. The double-sided fabric includes a continuous linear material (100) pressed by the right-directed and/or left-directed weaving pressing pieces and embedded into the double-sided fabric to form loop groups. Each loop group includes loops stitched and formed by one front knitting needle and two back knitting needles at two sides of the front knitting needle in a weaving process and in next weaving process. At least two of the loops groups are located in different weaving processes to cause a level drop in the continuous linear material (100) to form at least one curved portion (101).