Knitwear Perforated Structure Double Jersey Knitting Method
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Solution Overview
Problem
Existing methods for producing knitted fabrics struggle to combine fine meshes with large holes, as achieving one characteristic often compromises the other, and current machinery limitations restrict production output and flexibility in sports and underwear textiles.
Innovation Solution
A method using a double jersey knitting machine with a high needle gauge of ≥ 24 needles/inch, featuring latch needles and transfer needles, where transfer needles form loop accumulations with tuck loops that are reassigned to create holes of varying sizes and densities, allowing for both fine and large holes in the same fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If warp looms are used to produce stable hole structures, then hole stability is improved, but fabric elasticity deteriorates
Solution Approach 1:
The patent combines the hole-forming capability of warp looms with the elasticity of circular knitting machines by integrating a patterning device into the circular knitting machine, allowing both stable holes and fabric elasticity to coexist in the same garment
2Adaptability or versatility
If shedding technique is used for hole formation, then production flexibility is improved, but stitch stability deteriorates due to running stitches
Solution Approach 1:
The patent segments the hole formation process into two independent steps: first forming holes without shedding, then selectively removing stitches in a second knitting cycle, thereby maintaining stitch stability while preserving production flexibility
Solution Approach 2:
The patent performs preliminary hole formation in the first knitting cycle before the garment is subjected to tensile stress, and then reinforces the structure in a second cycle, preventing running stitches while maintaining flexibility
3Reliability
If double-jersey transfer circular knitting machines are used, then run-proof hole formation is improved, but machine fineness deteriorates due to space requirements of transfer needles
Solution Approach 1:
The patent extracts the transfer needles and spring mechanisms from the system, replacing them with a patterning device that forms holes directly during knitting, eliminating the space requirements that limited machine fineness while maintaining run-proof hole formation
4Adaptability or versatility
If needles with transfer springs are used, then hole formation capability is improved, but production output deteriorates due to limited needle availability
Solution Approach 1:
The patent makes all needles in the circular knitting machine capable of hole formation through the patterning device, rather than requiring specialized transfer needles, thereby increasing the number of active knitting positions and production output while maintaining hole formation capability
Data Source
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AI summary
The present invention relates to a method for producing knitwear formed at least partially as single jersey knitwear with a perforated structure, and to a functional textile which is based on knitwear formed at least partially as single jersey knitwear with a perforated structure. The problem addressed by the present invention is that of providing a knitting method which permits the production of knitwear which, firstly, has very fine knitting stitches and, secondly, perforated structures with relatively large holes, and therefore said knitwear meets, for example, the demands imposed on textiles used in sports articles or underwear. Furthermore, a corresponding functional textile is intended to be provided by the present invention. This problem is solved, firstly, by a method of the type in question mentioned above, wherein the knitwear is produced on a double jersey knitting machine with a first and a second needle carrier and a machine gauge of > 24 needles/inch, wherein the first needle carrier is arranged opposite the second needle carrier, the first needle carrier has a needle number/inch of latch-type needles corresponding to the machine gauge, and the second needle carrier has transfer needles, wherein the needle number/inch of the transfer needles is smaller by a factor of at least 2 than the needle number/inch of the latch-type needles of the first needle carrier, and wherein loop accumulations with at least one tuck loop per hole are formed with the transfer needles, and the tuck loops are subsequently transferred without or with at least one knitting stitch from the transfer needles onto the latch-type needles. The problem is furthermore solved by a functional textile which is obtainable by the method according to the invention.