Warp Knitting Tool Assembly with Filling Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional knitting tool designs struggle to maintain stability and prevent deformation at high gauges, leading to potential collisions and reduced fabric quality due to insufficient lateral support and web weakness, especially when trying to produce finer fabrics.
Innovation Solution
Incorporating a filling element between adjacent knitting tools on their side flanks, outside the grooves, to provide lateral support and reduce the thickness of the needles without compromising stability, allowing for a thinner, more manageable needle design that maintains load-bearing capacity and reduces collision risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of knitting needles is increased to produce finer fabrics, then the fineness of the knitted fabric is improved, but the webs between the grooves become too thin to provide sufficient lateral support
Solution Approach 1:
The filling element acts as an intermediary component positioned between adjacent knitting needles. It provides lateral support to the needles without requiring the webs between grooves to be thick, thus enabling high needle density while maintaining structural support.
Solution Approach 2:
Instead of providing support through the web thickness (one dimension), the filling element introduces support in the lateral dimension between needles. This shifts the support mechanism from vertical web structure to horizontal filling element structure.
2Manufacturing precision
If the thickness of knitting needles is reduced to enable finer fabrics, then the fineness of the knitted fabric is improved, but the lateral stability of the knitting needles is compromised
Solution Approach 1:
The filling element serves as a mediator that provides lateral stability to thin knitting needles. By positioning filling elements between adjacent needles, the system achieves needle stability without requiring increased needle thickness, thus maintaining fabric fineness.
3Weight of moving object
If the thickness of knitting needles is reduced, then the mass of the knitting needle is decreased, but the risk of collision with guide needles increases due to loss of lateral stability
Solution Approach 1:
The filling element acts as a protective intermediary that prevents lateral displacement of thin knitting needles. This mediation reduces the risk of collision with guide needles while allowing the use of lighter, thinner needles that reduce mass and improve productivity.
4Weight of moving object
If the thickness of knitting needles is reduced, then the mass of the knitting needle is decreased, but the load-bearing capacity is compromised
Solution Approach 1:
The filling element provides additional load-bearing support between adjacent knitting needles. This intermediary structure compensates for the reduced load-bearing capacity of thinner needles, allowing the system to use lighter needles while maintaining overall structural strength.
5Productivity
If conventional knitting needle designs are used at high gauges, then the number of knitting needles per inch is increased, but the webs between grooves become too weak and may break under lateral distortion forces
Solution Approach 1:
The filling element serves as a reinforcement intermediary that compensates for the weakened web structure. By introducing this additional support element between grooves, the system can accommodate higher needle densities without the webs becoming too thin and vulnerable to breaking.
Data Source
Figure 1
Figure 2~9
AI summary
A working tool arrangement (1) is described, comprising a tool holder (3) having several parallel grooves (10) and several working tools (2), each of which has a holding area (12) arranged in one of the grooves (10) and a working end (15, 16). The aim is to achieve a high degree of fineness. For this purpose, at least one filler element (18) is provided between adjacent working tools (2), arranged between the holding area (12) and the working end (15, 16).