Warp Thread Insertion in Flat Knitting Machines
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Solution Overview
Problem
Current methods for producing knitted fabrics on flat knitting machines face challenges in creating complex patterns and designs while achieving desired strength and extensibility, particularly in integrating warp threads effectively.
Innovation Solution
A method for inserting warp threads into knitted fabrics using a flat knitting machine with a needle bed, thread guide, and knitting system, where the thread feeder is moved between raised and lowered positions to position and insert warp threads, allowing for integration into the fabric without modifying existing knitting locks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If warp threads are inserted into knitted fabrics using conventional methods, then the fabric can achieve enhanced strength and design options, but the knitting machine requires complex modifications to existing knitting locks and mechanisms
Solution Approach 1:
The patent extracts the warp thread insertion function from the conventional knitting lock mechanism. Instead of modifying existing knitting locks to handle warp threads, the invention uses a separate thread guide system that operates independently, allowing warp threads to be inserted without interfering with or complicating the original knitting mechanism.
Solution Approach 2:
The patent segments the knitting machine into distinct functional zones: the original knitting mechanism remains unchanged while a separate thread guide system with movable thread feeds is introduced. This segmentation allows warp thread insertion to occur in parallel with the knitting process without requiring integration into the existing complex lock mechanisms.
2Adaptability or versatility
If the knitting machine is modified to insert warp threads, then warp thread integration is achieved, but the ease of manufacture and operation deteriorates due to required changes to knitting locks
Solution Approach 1:
The thread guide system is designed as a universal component that can work with standard knitting machines without modification. The movable thread feeds can guide warp threads through multiple positions and accommodate different knitting patterns, providing multi-functionality while maintaining compatibility with existing machinery.
Solution Approach 2:
The thread guide acts as an intermediary device between the warp thread source and the knitting needles. It mediates the insertion process by temporarily holding and positioning warp threads, allowing them to be integrated into the fabric without direct modification of the knitting locks or core machine structures.
3Manufacturing precision
If thread feeds are moved between raised and lowered positions to insert warp threads, then precise warp thread positioning is achieved, but the device complexity increases due to movable thread guide components
Solution Approach 1:
The thread feeds are designed to be movable between raised and lowered positions, transforming a static thread guide into a dynamic system. This dynamic capability allows precise positioning of warp threads at different stages of the knitting cycle, enabling accurate insertion while the movement mechanism itself remains relatively simple and integrated into the existing machine rhythm.
4Adaptability or versatility
If complex patterns and designs are created in knitted fabrics, then design versatility is improved, but the productivity and manufacturing efficiency deteriorate due to elaborate processing requirements
Solution Approach 1:
The warp thread insertion process operates continuously alongside the knitting process. The movable thread feeds are synchronized with the knitting cycle, allowing warp threads to be inserted without interrupting or slowing down the production of the basic knitted fabric, thereby maintaining productivity while enabling complex patterns.
Solution Approach 2:
The thread guide system prepares warp threads in advance by positioning them at the appropriate locations before the knitting needles arrive. This preliminary positioning action occurs during the needle return stroke or between knitting cycles, so that when the needles pass through, the warp threads are already correctly placed, eliminating the need for complex real-time adjustments during high-speed knitting.
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
The invention relates to a method for producing a knitted fabric with a warp thread inset on a knitting machine, in particular a flat knitting machine, comprising at least one needle bed with several associated knitting needles, at least one knitting system with at least one knitting lock, and at least one yarn guide with at least one yarn feed, wherein the at least one yarn feed is movable between a raised and a lowered position and parallel to the longitudinal direction of the needle bed, comprising the method steps: a. Moving the at least one raised yarn feed, which carries at least one warp thread, parallel to the longitudinal direction of the needle bed to a warp thread inset position, b. Lowering the at least one yarn feed, c. Extending at least one knitting needle intended for a warp thread application into a defined advanced position, so that it is arranged above the free-lying at least one warp thread, d.e. Raising the at least one yarn feed and shifting the yarn feed parallel to the needle bed longitudinal direction, f. Lowering the yarn feed, g. Removing the knitting needles pushed out in step c., g. Knitting the at least one warp thread with a thread for a base knit.