Warp Knitted Fabric Feeding Layout for Stable 200% Stretch
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Solution Overview
Problem
Current warp knitted fabric manufacturing methods face challenges in achieving high longitudinal elongation, as the use of elastic yarns leads to instability in tension and increased variation in elongation and shrinkage, making it difficult to produce fabrics with elongation of 200% or more, and existing solutions often result in discomfort due to excessive pressure around body parts like wrists and ankles.
Innovation Solution
The method involves using active feed means with a single follower roller arranged above two drive rollers to stabilize the tension of warp and inserting yarns, combined with a crochet warp knitting machine and tension control mechanisms, to consistently feed elastic yarns and achieve higher elongation, while minimizing power required for elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastic yarn is used to achieve high elongation, then the fabric can adapt to body size variation, but the yarn tension becomes unstable and variation in elongation and shrinkage increases
Solution Approach 1:
The patent changes the physical state of the yarn by pre-stretching the elastic yarn to a specific elongation ratio (50-200%) before knitting. This parameter change stabilizes the yarn's elastic properties during the knitting process, reducing tension fluctuation and improving reliability while maintaining the adaptability to body size variation.
2Ease of manufacture
If conventional warp knitting method is used, then the manufacturing process is simple, but the fabric cannot achieve longitudinal elongation of 200% or more
Solution Approach 1:
The patent applies preliminary action by pre-stretching the elastic yarn before it enters the knitting machine. This pre-treatment prepares the yarn in an optimized state for knitting, enabling the final fabric to achieve high longitudinal elongation of 200% or more while maintaining a relatively simple manufacturing process that only requires adding a stretching device before the knitting machine.
3Productivity
If operation speed of warp knitting machine is increased to improve productivity, then more fabric can be produced, but elastic yarn may be broken due to time lag in tension control
Solution Approach 1:
By pre-stretching the elastic yarn before knitting, the yarn's elastic properties are stabilized in advance. This preliminary preparation reduces the time lag effect during high-speed knitting, allowing the machine to operate at higher speeds without increasing yarn breakage risk, thus improving productivity while maintaining reliability.
4Object-affected harmful factors
If high elongation fabric is used to prevent body oppression, then comfort is improved, but more power is required to achieve the elongation
Solution Approach 1:
The patent changes the elastic properties of the yarn through pre-stretching, which modifies the stress-strain characteristics. This parameter change allows the fabric to achieve high elongation (200% or more) with reduced power requirement, as the pre-stretched yarn requires less force to extend further, thereby improving comfort without excessive power consumption.
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 approach allows for the stable production of warp knitted fabrics with longitudinal elongation of up to 200%, reducing pressure on the body and enhancing comfort by allowing a single size to fit a wider range, such as 1 to 2.5 times the original length, thus preventing hair fall and minimizing pain around wrists and ankles.
Implementation Method 1
feed the warp yarn and the inserting yarn to a warp knitting machine while increasing the elongation thereof
Data Source
AI summary
The invention addresses the problem of providing a warp knitted fabric manufacturing method capable of stably producing a warp knitted fabric wherein the longitudinal stretchability is 200%. To solve the problem, the invention is a warp knitted fabric manufacturing method that forms bands of a warp knitted structure with increased longitudinal stretchability by forming stitches with an elastic warp (2) while knitting in an elastic inserted yarn (3) in the warp direction and knitting in the weft (4) in the course direction, wherein: active feed means (30), which are obtained by placing a single follower roller (323) above two drive rollers (321, 322), are disposed on the respective paths of the warp (2) and the inserted yarn (3) to feed the warp (2) and the inserted yarn (3) to the warp knitting machine while increasing the respective elongation percentage. The active feed means (30) keep the respective feed rates of the warp (2) and the inserted yarn (3) constant while feeding same to the crochet warp knitting machine (40).