Warp Knitted Fabric with Segmented Guide Bar Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Warp knitted fabrics with a woven fabric appearance often suffer from suppressed stretch characteristics and inadequate tear strength due to the insertion yarn, which limits their application in requiring both stretch and durability.
Innovation Solution
A warp knitted fabric is created using yarns from at least three guide bars, where the back yarn forms a cord knit structure, and the front and middle yarns form alternate stitch and insertion structures in the warp direction, exposing them alternately on sinker loops to enhance both the design and physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If insertion yarn is used to create woven fabric appearance in warp knitted fabric, then the woven fabric appearance is achieved, but the stretch characteristic is suppressed
Solution Approach 1:
The fabric structure is segmented into distinct functional zones: insertion structures (forming woven appearance) and stitch formation structures (providing stretch). The front yarn and middle yarn are arranged alternately in the weft direction, with each forming stitch and insertion structures alternately in the warp direction. This segmentation allows the insertion structures to provide woven appearance while the stitch formation structures maintain stretch characteristics.
Solution Approach 2:
Different parts of the fabric have different functions: the insertion structures (formed by front and middle yarns exposed on sinker loops) provide woven fabric appearance, while the stitch formation structures (denbigh or cord knit structures) provide stretch capability. This local differentiation of function resolves the contradiction between appearance and stretch.
2Shape
If insertion yarn is used to create woven fabric appearance, then the woven fabric appearance is achieved, but the tear strength is degraded
Solution Approach 1:
The fabric is segmented into reinforcement structures (cord knit structure from back yarn) and appearance structures (insertion structures from front and middle yarns). The cord knit structure provides tear strength reinforcement while the insertion structures provide woven appearance, resolving the contradiction between appearance and strength.
Solution Approach 2:
The fabric uses a composite structure combining different knit structures (cord knit, denbigh knit, insertion structures) and different yarn positions (front, middle, back guide bars) to achieve both woven appearance and high tear strength. The back yarn forms a cord knit structure that reinforces the fabric against tearing.
3Shape
If wrinkle processing is performed on tricot knitted fabric to express wefts, then the woven fabric appearance is partially achieved, but the woven fabric appearance is insufficient and tear strength is degraded
Solution Approach 1:
Instead of applying wrinkle processing after knitting, the invention incorporates the woven fabric appearance directly into the knitting structure itself through the arrangement of front and middle yarns forming alternate stitch and insertion structures. This preliminary incorporation of the desired appearance eliminates the need for post-processing that would compromise strength.
Solution Approach 2:
The invention replaces the mechanical wrinkle processing step with a structural knitting approach. Instead of using external mechanical force (wrinkle processing) to create the woven appearance, the appearance is created through the inherent structure of the knitted fabric itself, using the guide bar arrangement and yarn feeding patterns.
Data Source
AI summary
A warp knitted fabric formed of yarns fed from at least three guide bars including front, middle, and back guide bars, in which a back yarn fed from the back guide bar forms a cord knit texture, a front yarn fed from the front guide bar and a middle yarn fed from the middle guide bar are arranged alternately in a weft direction, each of the front yarn and the middle yarn forms a stitch formation texture (a denbigh knit texture or a cord knit texture) and an insertion texture alternately in a warp direction, and the insertion texture formed by the front yarn and the insertion texture formed by the middle yarn are arranged alternately at least in the warp direction so that the front yarn and the middle yarn are exposed alternately at least in the warp direction on sinker loops of the back yarn.