Pair Sinker Loop Protrusion Control
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Solution Overview
Problem
The existing methods for knitting double fleece knit fabrics using a pair sinker often result in protrusion of the lay-in yarn on the front surface of the ground knit fabric due to fluctuations in the state of the yarns, sinkers, and environmental conditions, as the friction force between the lay-in yarn and the sinker is unpredictable, leading to inconsistent loop formation.
Innovation Solution
A pair sinker configuration with independently movable first and second sinkers, where the second sinker's insertion portion is designed to push the lay-in yarn's loop inward, ensuring it remains on the back surface of the ground knit fabric, even when environmental or yarn state changes occur, by moving radially inward and outward to control loop formation and prevent protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lay-in yarn is held by friction force between the lay-in yarn and the sinker to prevent loop loosening, then the loop of the lay-in yarn is maintained, but the friction force fluctuates depending on surface states, contact conditions, temperature, humidity, and lubricant presence, causing inconsistent control and protrusion of the loop root on the front surface
Solution Approach 1:
The patent replaces the friction-based mechanical holding system with a geometric constraint system. The stepped portion creates a physical barrier that mechanically prevents the lay-in yarn from moving outward, substituting unpredictable friction forces with deterministic geometric constraints. This resolves the contradiction by making loop control independent of environmental factors like temperature, humidity, and surface conditions.
Solution Approach 2:
The stepped portion acts as an intermediary element between the sinker and the lay-in yarn. Instead of relying on direct friction contact between the sinker surface and yarn, the stepped portion provides an intermediate geometric structure that physically blocks yarn movement. This intermediary mechanism ensures consistent loop control regardless of variations in yarn or sinker surface states.
2Productivity
If the sinker is separated from the lay-in yarn to allow the knitting needle to draw the tie-in yarn and knit-in yarn downward, then the knitting cycle progresses, but the loop of the lay-in yarn is drawn into the old loop and the root protrudes on the front surface
Solution Approach 1:
The stepped portion performs preliminary action by pre-positioning and pre-constraining the lay-in yarn loop before the knitting needle draws the tie-in and knit-in yarns downward. The geometric constraint is established in advance, preventing the loop root from being drawn into the old loop during the subsequent knitting cycle. This allows the knitting cycle to proceed at full speed without compromising loop position control.
Solution Approach 2:
The stepped portion applies preliminary anti-action by creating a physical barrier that opposes the downward drawing force of the knitting needle on the lay-in yarn loop. This counter-force is established before the harmful effect (loop protrusion) can occur, preventing the loop root from being drawn into the old loop while allowing the knitting cycle to continue efficiently.
3Reliability
If a pile-yarn holding stepped portion is used to hold the lay-in yarn during the knitting cycle, then the lay-in yarn is not loosened and loop protrusion is reduced, but the sinker structure becomes more complex and adjustment becomes more difficult
Solution Approach 1:
The sinker is segmented into distinct functional regions: the main sinker body and the stepped portion. This segmentation allows the stepped portion to be designed as a simple geometric feature integrated into the sinker structure, rather than a separate complex mechanism. The segmentation enables the stepped portion to perform the holding function while keeping the overall sinker structure relatively simple and easy to manufacture.
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
This configuration effectively suppresses the protrusion of the lay-in yarn on the front surface of the ground knit fabric, maintaining consistent loop formation regardless of changes in yarn or sinker states and environmental conditions, ensuring a stable and uniform double fleece knit fabric production.
Implementation Method 1
the second sinker's insertion portion is designed to push the lay-in yarn's loop inward, ensuring it remains on the back surface of the ground knit fabric
Implementation Method 2
a first sinker and a second sinker which are plate members movable independently from each other in a radial direction of a rotating cylinder of the circular knitting machine
Data Source
Figure 1
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Figure 4
AI summary
A pair sinker that can suppress protrusion of a lay-in yarn on a front surface of a ground knit fabric even in a case where a state of each yarn, a state of the pair sinker, or a surrounding environment is changed, a circular knitting machine including the pair sinker, and a knitting method for knitting a double fleece knit fabric by the circular knitting machine including the pair sinker are achieved. A pair sinker 11 are constituted by a first sinker 12 and a second sinker 13 respective base portions of which are inserted in a same sinker groove 7a of a circular knitting machine 1, the first sinker 12 includes a upper support portion 12c that supports a lay-in yarn r, a tie-in yarn t, and a knit-in yarn k and a lower support portion 12b located more downward than the upper support portion 12c, the second sinker 13 includes an insertion portion 13b that is inserted in a loop Rr of the lay-in yarn and a second sinker engaging portion 13c that pushes in the lay-in yarn r and the tie-in yarn t, and an upper end surface 13e of the insertion portion 13b is arranged in a position located more downward than an upper end surface 12g of the upper support portion 12c and more upward than an upper end surface 12h of the lower support portion 12b.