Warp Knitted Fastener Stringer Stitch Density Optimization
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Solution Overview
Problem
Conventional knitted fastener stringers with a double structure fixing chain stitch yarn impair the flexibility and texture of the fastener tape, restrict movement of fastener elements, and limit production efficiency due to dense knit structures and high stitch density, making it difficult to bend and increasing manufacturing costs.
Innovation Solution
A knitted fastener stringer with a warp knit structure featuring a fixing chain stitch yarn with one first and one second needle loop per pitch, interlacing with the ground structure, allowing for reduced stitch density and increased flexibility, while maintaining secure fastening of fastener elements, and incorporating weft inserted yarns for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixing chain stitch yarn with double structure (two first and two second needle loops) is used to securely fasten fastener elements, then the fastening reliability is improved, but the flexibility and texture of the fastener tape deteriorate
Solution Approach 1:
The patent applies local quality by differentiating the function of needle loops: first needle loops create a dense ground structure in specific areas for stability, while second needle loops are strategically positioned to fasten fastener elements. This localized differentiation allows the fastener tape to have both secure fastening capability and maintained flexibility in different regions.
Solution Approach 2:
The fixing chain stitch yarn is segmented into distinct first and second needle loops with different functions. First needle loops form the ground structure, while second needle loops are dedicated to fastening fastener elements. This segmentation allows each component to optimize its function without compromising the overall flexibility of the tape.
2Stability of the object's composition
If a dense knit structure with high stitch density is used to stabilize the element attaching portion, then the dimensional stability is improved, but the knitting speed decreases and manufacturing costs increase
Solution Approach 1:
The patent changes the structural parameters of the fixing chain stitch yarn by reducing from two first and two second needle loops to one first and one second needle loop per pitch. This parameter change maintains sufficient dimensional stability while significantly improving knitting speed and reducing manufacturing costs.
Solution Approach 2:
Instead of using excessive needle loops (two first and two second loops) to ensure stability, the patent applies partial action with one first and one second needle loop, which provides sufficient dimensional stability for the element attaching portion while enabling faster knitting speeds and lower production costs.
3Strength
If multiple needle loops are formed at each pitch to firmly fix fastener elements, then the coupling strength is improved, but the number of stitches increases and knitting efficiency decreases
Solution Approach 1:
The patent optimizes the number of needle loops per pitch from four (two first and two second loops) to two (one first and one second loop). This parameter change maintains adequate coupling strength between the fastener element and the tape while doubling the knitting efficiency.
Data Source
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AI summary
In a knitted fastener stringer (1) of the invention, an element attaching portion (12) of a fastener tape (10) is configured by using at least a fixing chain stitch yarn (35) which fixes a fastener element (20), and this fixing chain stitch yarn (35) comprises a first needle loop (35a) which is knitted into a ground structure and a second needle loop (35b) which fixes upper and lower leg portions (22). Also, the one first and one second needle loops (35a, 35b) of the fixing chain stitch yarn (35) is formed at each one pitch of the fastener element (20). As a result, it is possible to achieve an improvement of productivity and a large reduction of a manufacturing cost by increasing a knitting speed when knitting the knitted fastener stringer (1) and further to stably obtain flexibility and a soft texture in the knitted fastener stringer (1) .