Spacer Knitted Fabric Elasticity via Plating Thread Floats
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Solution Overview
Problem
Existing spacer knitted fabrics have limited variability in properties such as elasticity and extensibility, primarily due to the constraints of circular edge knitting machines, which restrict the ability to change transverse elasticity and stretch properties.
Innovation Solution
The integration of additional float or plating threads with specific yarn qualities and arrangements on one needle bed of a circular edge knitting machine, allowing for the production of fabrics with varied elasticity and stability by selecting the number and arrangement of floats, and using suitable yarns like polyester or elastomer threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional circular edge knitting machines are used to produce spacer fabrics, then the fabric structure is stable and production is reliable, but the transverse elasticity and extensibility properties are limited and cannot be varied within wide limits
Solution Approach 1:
The patent applies local quality by differentiating the function of needles between the two needle beds. One needle bed (cylinder needles) produces the base fabric structure, while the other needle bed (dial needles) produces the spacer effect with floats. This local differentiation allows independent optimization of each needle bed's function, enabling wide variability in fabric properties without requiring complete redesign of the entire knitting machine.
Solution Approach 2:
The patent segments the knitting process into two independent fabric productions - one fabric with cylinder needles and another with dial needles - connected by spacer threads. This segmentation allows each needle bed to be optimized for specific functions and enables independent variation of fabric properties through selective needle assignment and yarn selection, resolving the contradiction between adaptability and device complexity.
2Adaptability or versatility
If all needles of one needle bed are used to produce one fabric, then the production process is simple and reliable, but the transverse elasticity and stretch properties can only be changed in small limits through yarn selection
Solution Approach 1:
The patent applies parameter changes by varying the number, arrangement, and type of needles used in each needle bed, as well as changing yarn properties (elastane content, float length). This allows wide variability in transverse elasticity and stretch properties while maintaining the basic two-needle-bed production process, thus achieving adaptability without sacrificing manufacturing simplicity.
Solution Approach 2:
The patent introduces dynamics by allowing flexible assignment of needles to different functions (knitting vs. floating) and enabling variable float arrangements. This dynamic configuration capability permits wide adjustment of fabric elasticity and stretch properties while maintaining a relatively simple production process using existing knitting machine architecture.
3Adaptability or versatility
If floats are incorporated into selected courses with specific yarn qualities, then fabric properties such as stability and elasticity can be varied, but the production process becomes more complex
Solution Approach 1:
The patent applies local quality by assigning specific functions to specific needle beds and yarns. One needle bed produces the base fabric with certain yarns, while the other needle bed produces the spacer effect with floats using different yarns. This local differentiation enables property variation through yarn and needle selection without requiring complex overall process changes, resolving the contradiction between adaptability and process complexity.
Data Source
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AI summary
The invention relates to a spacer knitted fabric which is preferably produced by a circular knitting machine and comprises two material webs connected by spacer threads (21a, 21b). One of the two material webs contains a base knitted fabric that is produced with only one ground thread (19), while the other material web contains a base knitted fabric which is produced from one ground thread (11) and is additionally provided with at least one plating thread (12) in at least selected rows of stitches (1, 4). According to the invention, said plating thread is inserted in selected stitches (15) of these rows of stitches (1, 4) in addition to the ground thread (11) and floats therebetween. The invention further relates to a method and a knitting machine for producing such a spacer knitted fabric.