Circular Knitting Needle Track Layout for Pure Yarn-Dyed Front Loops
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Solution Overview
Problem
Conventional yarn-dyed fabrics exhibit impure color development due to the visibility of non-color-developing ground yarn within front loops, leading to blurred patterns.
Innovation Solution
A circular knitting machine with specialized tracks for first and second knitting needles to form front and back loops using single-colored yarns, ensuring each front loop is composed of a single colored yarn, enhancing color purity by eliminating the need for relative position changes between face and ground yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If face yarn and ground yarn are knitted together in conventional yarn-dyed fabrics, then color variation is achieved through altering relative positions, but the ground yarn remains visible within front loops causing impure color appearance
Solution Approach 1:
The patent divides the knitting process into separate tracks: a first track for knitting front loops using only face yarn, and a second track for knitting back loops using both face yarn and ground yarn. This segmentation ensures that front loops contain only color-developing yarn while back loops provide structural support, eliminating the visibility of ground yarn in front loops and achieving pure color appearance.
Solution Approach 2:
The patent applies different knitting configurations to different regions of the fabric: front loops are knitted with single-color face yarn for pure color display, while back loops are knitted with both face yarn and ground yarn for structural integrity. This local differentiation allows each region to fulfill its specific function without compromising the other.
2Strength
If ground yarn is used together with color-developing yarn, then structural support is provided, but the non-color-developing yarn reduces color clarity when viewed straight at front loops
Solution Approach 1:
The patent segments the fabric into front loops and back loops with distinct yarn compositions. Front loops use only color-developing face yarn to maximize color clarity, while back loops incorporate both face yarn and ground yarn to provide structural support. This spatial segmentation resolves the conflict between structural strength and color clarity.
Solution Approach 2:
The patent resolves the conflict by moving the ground yarn from the front dimension (where color clarity is critical) to the back dimension (where structural support is needed). The ground yarn is positioned in the back loops where it does not interfere with the visual appearance of front loops, thus maintaining both structural integrity and color clarity.
3Adaptability or versatility
If relative positions of face yarn and ground yarn are altered to achieve color variation, then pattern diversity is improved, but the ground yarn remains visible causing blurred patterns
Solution Approach 1:
The patent segments the knitting tracks so that front loops are exclusively knitted with face yarn for sharp pattern definition, while back loops incorporate ground yarn for structural support. This allows pattern diversity to be achieved through face yarn positioning without ground yarn interfering with pattern sharpness.
Solution Approach 2:
The patent extracts the ground yarn from the front loop formation process, removing it from the color-display region. Ground yarn is retained only in back loops where it provides structural support without blurring patterns. This extraction eliminates the harmful effect of ground yarn visibility while preserving its structural function.
Data Source
AI summary
A circular knitting machine for knitting a double-sided yarn-dyed fabric includes a cylinder, a dial, at least one yarn feeder and at least one needle selector. The cylinder includes first knitting needles configured to form front loops of the fabric. The dial includes second knitting needles configured to form back loops of the fabric. The yarn feeder feeds a first colored yarn and a second colored yarn. Each first knitting needle has a first track and a second track partially overlapped with the first track. The first knitting needle draws only the first colored yarn to form the front loop along the first track, and draws only the second colored yarn to form the front loop along the second track. Each second knitting needle only has a single track to draw both the first colored yarn and the second colored yarn to form the back loop.