Circular Knitting Machine Thread Selection for Intarsia Material Savings
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Solution Overview
Problem
Existing circular knitting machines consume unnecessary thread material when producing patterned fabrics, especially for Intarsia patterns, as special threads are floated on the reverse side and not efficiently managed, leading to material waste and impaired fabric elasticity.
Innovation Solution
A circular knitting machine with a thread-selection device that supplies threads only to specific areas on the fabric circumference for pattern formation, allowing threads to be cut off between Intarsia portions and reused, eliminating the need for threads to float on the reverse side, and featuring a thread-clamping and feed device with a transport unit and suction funnel for precise thread management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If threads are supplied to all needles continuously in conventional circular knitting machines, then pattern production is possible, but thread material consumption increases unnecessarily
Solution Approach 1:
The thread supply system is segmented by needle position, with individual thread selection capability for each needle or needle group. The thread-selection device divides the knitting circumference into segments that can be independently supplied with different threads, allowing threads to be supplied only where needed for pattern formation rather than continuously to all needles.
Solution Approach 2:
The thread supply system is made dynamic and adjustable, enabling the machine to adapt thread distribution according to the specific pattern requirements. The thread-selection device can dynamically change which needles receive which threads based on the pattern design, optimizing material usage for different pattern types and positions.
2Stability of the object's composition
If threads are floated on the reverse side for Intarsia patterns, then pattern continuity is maintained, but fabric elasticity is impaired
Solution Approach 1:
The harmful floating threads on the reverse side are extracted and removed from the system. Instead of allowing threads to float continuously across the reverse side, the invention cuts off threads at the end of each Intarsia portion and prevents their continuation, thereby eliminating the elasticity-impairing floating thread structure while maintaining pattern integrity through precise thread placement and cutting.
Solution Approach 2:
Threads are discarded (cut off) at the end of each Intarsia portion where they are no longer needed for pattern formation. This prevents the formation of continuous floating threads on the reverse side. The thread supply system then recovers by supplying fresh threads to the next Intarsia portion, optimizing both pattern continuity and fabric elasticity.
3Duration of action of stationary object
If thread change points are removed from tubular knitted fabric, then fabric integrity is maintained, but production efficiency decreases
Solution Approach 1:
The thread-selection device performs preliminary thread management by precisely controlling thread supply to specific needles and cutting threads at appropriate points during the knitting process. This preliminary action ensures that thread change points do not require post-production removal, as threads are already optimally positioned and trimmed during manufacturing, maintaining both fabric integrity and production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significant thread material savings are achieved, maintaining fabric elasticity, and allowing for the production of complex patterns without additional sewing work, as threads are efficiently managed and reused, reducing material waste and enabling seamless integration of reinforcement or conductive regions.
Implementation Method 1
If the thread is transported by an air flow, no mechanical parts require to be moved for the thread transport.
Implementation Method 2
the thread-selection device having a suction funnel for receiving the starting ends of the threads. Hence the starting ends of the threads can be fixed until the first stitch has been formed with the thread.
Data Source
AI summary
A single- or double-knit circular knitting machine having a cylinder (11) equipped with cylinder needles and/or a dial equipped with dial needles for the production of single- or double-jersey knitted webs, which machine has at least one thread-selection device, threads being able to be supplied to any cylinder- and/or dial needle by the thread-selection device.