US20230366137A1

US20230366137A1 - Knitting Machine And Method For Knitting A Fabric By Yarn Plating With Multiple Yarns

Info

Publication number: US20230366137A1
Application number: US18/026,051
Authority: US
Inventors: Hetti Arachchige Malaka Chathuranga Perera; Dodangodage Indika Sanjeewa Wickramaratne; Pahalagamage Priyantha Saman Kumara
Original assignee: Mas Innovation Pvt Ltd
Current assignee: Mas Innovation Pvt Ltd
Priority date: 2020-09-14
Filing date: 2021-09-13
Publication date: 2023-11-16
Also published as: WO2022055434A1; JP2023543156A; GB2613995A; GB202304216D0

Abstract

The present disclosure generally relates to a knitting machine (100) for knitting a fabric by yarn plating. The knitting machine (100) comprises: a yarn feeder set (120) configured for reciprocating motion along the bed (102) and for feeding yarns (122) to the knitting needles (104), the yarn feeder set (120) comprising: a first hole (124a) for feeding a first yarn (122a) at a first angle with respect to the bed (102); a second hole (124b) for feeding a second yarn (122b) at a second angle with respect to the bed (102), the second angle greater than the first angle; and a third hole (124c) for feeding a third yarn (122c) at a third angle with respect to the bed (102), the third angle greater than the second angle, wherein knitting needles (104) form plated yarn loops comprising the third yarn (122c) interposed between the first and second yarns (122a, 122b).

Description

CROSS REFERENCE TO RELATED APPLICATION(S)

The present disclosure claims the benefit of Singapore Patent Application No. 10202008964T filed on 14 Sep. 2020, which is incorporated in its entirety by reference herein.

TECHNICAL FIELD

The present disclosure generally relates to a knitting machine. More particularly, the present disclosure describes various embodiments of a knitting machine and a machine knitting method for knitting a fabric by yarn plating with multiple yarns.

BACKGROUND

Various fabrics or products made from fabric materials, such as garments, can be manufactured by weaving or knitting. Knitted fabrics are created by inter-looping of yarns which may either be weft yarns or warp yarns. One method of producing knitted fabrics is flat knitting in which the fabric is turned periodically to alternatingly work on both sides. Flat knitting can be done manually by hand or by using a flatbed knitting machine to produce knitted fabrics in an automated manner. A flatbed knitting machine commonly uses a single yarn to produce knitted fabrics. In some cases, a flatbed knitting machine can use two yarns to produce knitted fabrics which may be referred to as plated structures. Japan patent 6562890 describes such a knitting machine that uses two yarns.

SUMMARY

According to a first aspect of the present disclosure, there is a knitting machine for knitting a fabric by yarn plating, the knitting machine comprising:

an elongated bed;
a plurality of knitting needles arranged along the bed, each knitting needle configured for reciprocating motion; and
a yarn feeder set configured for reciprocating motion along the bed and for feeding yarns to the knitting needles, the yarn feeder set comprising:
- a first hole for feeding a first yarn at a first angle with respect to the bed;
- a second hole for feeding a second yarn at a second angle with respect to the bed, the second angle greater than the first angle; and
- a third hole for feeding a third yarn at a third angle with respect to the bed, the third angle greater than the second angle,
wherein the reciprocating motion of the knitting needles repetitively engage and disengage the first to third yarns collectively to thereby form plated yarn loops on the fabric, each plated yarn loop comprising the third yarn interposed between the first and second yarns.

According to a second aspect of the present disclosure, there is a method for machine knitting a fabric by yarn plating, the method comprising:

arranging a plurality of knitting needles along an elongated bed;
reciprocating a yarn feeder set comprising a first hole, a second hole, and a third hole;
feeding a first yarn through the first hole at a first angle with respect to the bed;
feeding a second yarn through the second hole at a second angle with respect to the bed, the second angle greater than the first angle;
feeding a third yarn through the third hole at a third angle with respect to the bed, the third angle greater than the second angle;
reciprocating the knitting needles to repetitively engage and disengage the first to third yarns collectively; and
forming plated yarn loops on the fabric by the repetitive engagement and disengagement of the first to third yarns collectively, each plated yarn loop comprising the third yarn interposed between the first and second yarns.

A knitting machine and a machine knitting method according to the present disclosure is thus disclosed herein. Various features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the present disclosure, by way of non-limiting examples only, along with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a knitting machine in accordance with embodiments of the present disclosure.

FIG. 2 is an illustration of a latch needle of the knitting machine in accordance with embodiments of the present disclosure.

FIG. 3A to FIG. 3E are illustrations of a reciprocating motion of the latch needle in accordance with embodiments of the present disclosure.

FIG. 4 is an illustration of a yarn feeder set of the knitting machine in accordance with some embodiments of the present disclosure.

FIG. 5 is a flowchart illustration of a method for machine knitting a fabric in accordance with embodiments of the present disclosure.

FIG. 6A and FIG. 6B are illustrations of another yarn feeder set in accordance with some embodiments of the present disclosure.

FIG. 7A and FIG. 7B are further illustrations of the yarn feeder set of FIG. 4 in accordance with some embodiments of the present disclosure.

FIG. 8A and FIG. 8B are yet further illustrations of the yarn feeder set of FIG. 4 in accordance with some embodiments of the present disclosure.

FIG. 9A and FIG. 9B are illustrations of another yarn feeder set in accordance with some embodiments of the present disclosure.

FIG. 10A and FIG. 10B are cross-sectional illustrations of yarns in the latch needle accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

For purposes of brevity and clarity, descriptions of embodiments of the present disclosure are directed to a knitting machine and a machine knitting method in accordance with the drawings. While aspects of the present disclosure will be described in conjunction with the embodiments provided herein, it will be understood that they are not intended to limit the present disclosure to these embodiments. On the contrary, the present disclosure is intended to cover alternatives, modifications and equivalents to the embodiments described herein, which are included within the scope of the present disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by an individual having ordinary skill in the art, i.e. a skilled person, that the present disclosure may be practiced without specific details, and/or with multiple details arising from combinations of aspects of particular embodiments. In a number of instances, known systems, methods, procedures, and components have not been described in detail so as to not unnecessarily obscure aspects of the embodiments of the present disclosure.
In embodiments of the present disclosure, depiction of a given element or consideration or use of a particular element number in a particular figure or a reference thereto in corresponding descriptive material can encompass the same, an equivalent, or an analogous element or element number identified in another figure or descriptive material associated therewith.
References to “an embodiment / example”, “another embodiment / example”, “some embodiments / examples”, “some other embodiments / examples”, and so on, indicate that the embodiment(s) / example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment / example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an embodiment / example” or “in another embodiment / example” does not necessarily refer to the same embodiment / example.
The terms “comprising”, “including”, “having”, and the like do not exclude the presence of other features / elements / steps than those listed in an embodiment. Recitation of certain features / elements / steps in mutually different embodiments does not indicate that a combination of these features / elements / steps cannot be used in an embodiment.
As used herein, the terms “a” and “an” are defined as one or more than one. The use of “/” in a figure or associated text is understood to mean “and/or” unless otherwise indicated. The recitation of a particular numerical value or value range herein is understood to include or be a recitation of an approximate numerical value or value range. The term “set” is defined as a non-empty finite organization of elements that mathematically exhibits a cardinality of at least one (e.g. a set as defined herein can correspond to a unit, singlet, or single-element set, or a multiple-element set), in accordance with known mathematical definitions. The terms “first”, “second”, “third”, etc. are used merely as labels or identifiers and are not intended to impose numerical requirements on their associated terms. The term “each other” represents a reciprocal relation between two or more elements.
Representative or exemplary embodiments of the present disclosure describe a knitting machine 100, such as a type of flatbed knitting machine, for knitting a fabric by yarn plating with multiple yarns, with reference to FIG. 1 . The knitting machine 100 includes an elongated bed 102 and a plurality of knitting needles 104 arranged along the elongated bed 102 for knitting a fabric. Specifically, each knitting needle 104 is configured for reciprocating motion or reciprocation. The knitting needles 104 may be arranged in at least one row such that they may be equally distributed, i.e. equally spaced apart, along a longitudinal axis of the elongated bed 102. It will be appreciated that the knitting needles 104 may be spaced apart at smaller or greater intervals from each other, such as to increase or decrease the knitting density, or at different intervals from each other. Reciprocation or reciprocating motion is a repetitive up-and-down or back-and-forth linear motion. Particularly, each knitting needle 104 is configured to move repetitively back and forth, preferably perpendicular to the longitudinal axis of the elongated bed 102.
In some embodiments, the knitting machine 100 further includes a carriage 106 configured for reciprocating motion along the elongated bed 102 to cause the reciprocating motion of the knitting needles 104. The reciprocation or reciprocating motion of the carriage 106 is such that the carriage 106 moves repetitively back and forth along the longitudinal axis of the elongated bed 102 and between both ends of the elongated bed 102. An actuation mechanism is installed in the knitting machine 100 and coupled to the carriage 106 to move the carriage 106 in a reciprocating motion. For example, the actuation mechanism includes a motor that generates circular motion and a crack that converts the circular motion into reciprocating linear motion of the carriage 106. The actuation mechanism includes a cam mechanism disposed under the elongated bed 102 to repetitively move the knitting needles 104 in a reciprocating motion according to the reciprocation of the carriage 106. As the carriage 106 passes across each knitting needle 104, the cam mechanism extends the knitting needle 104 outwards and retracts it inwards. This movement of the knitting needle 104 is repeated as the carriage 106 reciprocates back and forth across the knitting needle 104.
In some embodiments as shown in FIG. 1 , the elongated bed 102 is an inverted V-shaped flatbed having a front flatbed section and a back flatbed section. The front and back flatbed sections meet at a vertex which is preferably at a right angle. The plurality of knitting needles 104 are separated into a front row of knitting needles 104 and a back row of knitting needles 104. The front and back rows of knitting needles 104 are arranged at the front flatbed section and back flatbed section, respectively. As the carriage 106 passes over each front knitting needle 104, the cam mechanism extends and retracts, as appropriate, the front knitting needle 104 along a lateral axis perpendicular to the longitudinal axis and parallel to the front flatbed section. Similarly, as the carriage 106 passes over each back knitting needle 104, the cam mechanism extends and retracts, as appropriate, the back knitting needle 104 along a lateral axis perpendicular to the longitudinal axis and parallel to the back flatbed section.
In some embodiments, the knitting needles 104 are latch needles 104. As shown in FIG. 2 , each of the latch needles 104 has a needle stem 108, a hook 110 formed at the end (also referred to as the head) of the needle stem 108, and a latch 112 rotatably joined to the needle stem 108 for opening and closing the hook 110. The moving latch needle 104 and the opening and closing of the hook 110 engage and disengage a yarn to thereby form a plated yarn loop.
With reference to FIG. 3A as an arbitrary starting point of the reciprocating motion of a latch needle 104, as the latch needle 104 begins extending outwards, a first yarn loop 114 moves the latch 112 and opens the hook 110. As shown in FIG. 3B, as the latch needle 104 continues to extend outwards, the first yarn loop 114 is disengaged from the hook 110 and latch 112. The open hook 110 then engages a new yarn 116 that is being fed to the latch needle 104. As shown in FIG. 3C, as the latch needle 104 begins retracting inwards, the new yarn 116 remains engaged in the open hook 110 and the latch 112 engages the first yarn loop 114. As shown in FIG. 3D, as the latch needle 104 continues to retract inwards, the first yarn loop 114 moves the latch 112 and closes the hook 110. The latch needle 104 continues to retract inwards and pulls the new yarn 116, which is held in the closed hook 110. As shown in FIG. 3E, the new yarn 116 is pulled through the first yarn loop 114 and forms a second yarn loop 118, thereby creating an inter-looping yarn structure. It will be appreciated that each latch needle 104 in the rows of latch needles 104 move repetitively in a similar manner during knitting of the fabric. When a row of latch needles 104 extend outwards and retract inwards repeatedly, a row of inter-looping yarn loops or plated yarn loops is created on the fabric.
In some embodiments, other types of knitting needles 104 may be used instead of the latch needles 104 described above. For example, the knitting needles 104 may be bearded needles that have beard-like hooks. For example, the knitting needles 104 may be compound needles that have sliders that open and close the hooks. It will be appreciated that the knitting actions of the bearded needles and compound needles will be readily understood by the skilled person.
As stated above, the knitting machine 100 is configured for knitting the fabric by yarn plating with multiple yarns 122. Yarn plating is a technique of simultaneous knitting with multiple yarns 122 that may have different properties, such as in colour, material, and other functional properties, to produce desired effects on the fabric.
The yarns 122 may include a first yarn 122 a, a second yarn 122 b, and a third yarn 122 c. The knitting machine 100 includes a yarn feeder set 120 configured for feeding the yarns 122 to the knitting needles 104 for knitting the fabric by the moving knitting needles 104. The yarn feeder set 120 is further configured for reciprocating motion along the elongated bed 102, i.e. moving repetitively back and forth along the longitudinal axis of the elongated bed 102 and between both ends of the elongated bed 102. In some embodiments, the yarn feeder set 120 is coupled with the carriage 106 such that they move in tandem with each other, while the carriage 106 reciprocates back and forth along the elongated bed 102 to control the reciprocating motion of the knitting needles 104 during knitting of the fabric. In some other embodiments, the knitting machine 100 includes an actuation mechanism for reciprocating the yarn feeder set 120 independently of the carriage 106. The actuation mechanism may include one or more servo motors for effecting the reciprocating motion of the yarn feeder set 120.
As shown in FIG. 4 , the yarn feeder set 120 includes a first hole 124 a for feeding the first yarn 122 a at a first angle with respect to the elongated bed 102, a second hole 124 b for feeding the second yarn 122 b at a second angle with respect to the elongated bed 102, and a third hole 124 c for feeding the third yarn 122 c at a third angle with respect to the elongated bed 102. The angles are acute angles measured between the feeding directions of the respective yarns 122 and the longitudinal axis of the elongated bed 102. The holes 124 are arranged and configured with certain dimensions and geometry so that the yarns 122 do not entangle each other when they are fed to the knitting needles 104 for knitting. Specifically, the second angle is greater than the first angle, and the third angle is greater than the second angle. Preferably, each angle is less than 45°.
In various embodiments of the present disclosure as shown in FIG. 5 , there is a method 200 for machine knitting a fabric by yarn plating. Particularly, the method 200 is performed using the knitting machine 100 or other similar machines / systems. The method 200 includes a step 202 of arranging the plurality of knitting needles 104 along the elongated bed 102 for knitting the fabric. The method 200 includes a step 204 of reciprocating the yarn feeder set 120 along the elongated bed 102, the yarn feeder set 120 including the first hole 124 a, second hole 124 b, and third hole 124 c.
The method 200 includes steps of feeding yarns 122 to the knitting needles 104 for knitting the fabric. The feeding steps include a step 206 of feeding a first yarn 122 a through the first hole 124 a at a first angle with respect to the elongated bed 102. The feeding steps include a step 208 of feeding a second yarn 122 b through the second hole 124 b at a second angle with respect to the elongated bed 102, the second angle being greater than the first angle. The feeding steps include a step 210 of feeding a third yarn 122 c through the third hole 124 c at a third angle with respect to the elongated bed 102, the third angle being greater than the second angle.
The method 200 includes a step 212 of reciprocating the knitting needles 104 to repetitively engage and disengage the first to third yarns 122 collectively. Specifically, the first yarn 122 a, second yarn 122 b, and third yarn 122 c are fed through the first hole 124 a, second hole 124 b, and third hole 124 c, respectively, at the same time so that each time a knitting needle 104 engages or disengages the yarns 122, all of the first yarn 122 a, second yarn 122 b, and third yarn 122 c are simultaneously engaged or disengaged, respectively, by the knitting needle 104.
The method 200 includes a step 214 of forming plated yarn loops on the fabric by the repetitive engagement and disengagement of the first to third yarns 122 collectively. Therefore, the first yarn 122 a, second yarn 122 b, and third yarn 122 c are fed through the first hole 124 a, second hole 124 b, and third hole 124 c, respectively, at the same time so that the moving knitting needles 104 repetitively engage and disengage the first to third yarns 122 collectively to thereby form the plated yarn loops on the fabric.
The knitting machine 100 and the method 200 can thus be used to knit the fabric by forming the plated yarn loops as described above. Each plated yarn loop includes all of the first yarn 122 a, second yarn 122 b, and third yarn 122 c. In forming each plated yarn loop, the yarns 122 are fed to the knitting needles 104 such that they do not entangle each other, preventing the yarns 122 from twisting / crossing each other. Additionally, due to the angular relationship of the first to third yarns 122, each plated yarn loop includes the third yarn 122 c interposed between the first yarn 122 a and second yarn 122 b. This allows a knitted fabric to be formed with three different yarn materials in a layered arrangement.
In some embodiments as shown in FIG. 6A, the yarn feeder set 120 includes a sole yarn feeder device 130 having the first to third holes 124 for yarn plating. The sole yarn feeder device 130 includes a body structure having the holes 124 formed thereon. The first hole 124 a is positioned below the second hole 124 b which is positioned below the third hole 124 c. This allows the second angle of the feeding line of the second yarn 122 b through the second hole 124 b to be greater than the first angle of the feeding line of the first yarn 122 a through the first hole 124 a and to be smaller than the third angle of the feeding line of the third yarn 122 c through the third hole 124 c. Additionally, the holes 124 are designed with suitable distances between the holes 124, suitable distances of the holes 124 with respect to the elongated bed 102, suitable and sizes and shapes of the holes 124. Thus, the holes 124 are arranged and configured with certain dimensions and geometry so that the yarns 122 do not entangle / twist / cross each other when they are fed to the knitting needles 104 for knitting.
In one embodiment, the positions of the holes 124 are fixed with respect to each other. In another embodiment, the sole yarn feeder device is configured such that at least one of the first to third holes 124 is positionally adjustable with respect to the remaining holes 124. Preferably, all of the holes 124 are positionally adjustable to allow for greater freedom of adjustment, particularly for making the knitting machine 100 suitable for use with different types of yarns 122.
As shown in FIG. 6B, the sole yarn feeder device 130 may include a sleeve structure 132 and a plurality of peripheral structures 134 cooperative with each other to positionally adjust the holes 124. The sleeve structure 132 is arranged to receive the first to third yarns 122 therethrough and the peripheral structures 134, which may be in the form of annular structures or rings, are arranged with the sleeve structure 132 to form the holes 124. For example, the sleeve structure 132 has a slit 136 and the peripheral structures 134 are positioned with respect to the slit 136 to form the respective holes 124. At least one of the peripheral structures 136 may be moveable along the sleeve structure 132 to positionally adjust at least one of the holes 124 with respect to the remaining holes 124.
In some embodiments as shown in FIG. 4 , the yarn feeder set 120 includes a first yarn feeder device 140 and a second yarn feeder device 142 for yarn plating. The first yarn feeder device 140 includes two of the first to third holes 124 and the second yarn feeder device 142 includes the remaining hole 124. Preferably, the first yarn feeder device 140 includes the first hole 124 a and second hole 124 b, and the second yarn feeder device 142 includes the third hole 124 c. Additionally, the yarn feeder set 120 reciprocates along the elongated bed 102 such that the first yarn feeder device 140 and second yarn feeder device 142 move in tandem with each other and the first feeder device 140 always leads or trails the second feeder device 142 along a displacement direction of the yarn feeder set 120.
In one embodiment, the knitting machine 100 includes the carriage 106 coupled with the yarn feeder set 120 such that they move in tandem with each other. When the carriage 106 is moving along displacement direction from right to left as shown in FIG. 7A, the first yarn feeder device 140 is leading the second yarn feeder device 142. All of the yarns 122 are tensioned and being pulled from right to left. The carriage 106 reverses direction when the carriage 106 reaches one end of the reciprocating motion. When the carriage 106 is moving along a reverse displacement direction from left to right as shown in FIG. 7B, the first yarn feeder device 140 is leading the second yarn feeder device 142. All of the yarns 122 are tensioned and being pulled from left to right. Thus, the first feeder device 140 always leads the second feeder device 142. However, it will be appreciated that other configurations are similarly possible, such as where the first feeder device 140 always trails the second feeder device 142.
The carriage 106 may include a rotation mechanism for coupling the first feeder device 140 and second feeder device 142 to the carriage 106. The rotation mechanism is configured to reverse the orientation of the first feeder device 140 and second feeder device 142 at both ends of the reciprocating motion of the carriage 106. More specifically, at each end of the reciprocating motion, the carriage 106 maintains its orientation but begins to move in the reverse displacement direction, while the rotation mechanism reverses the orientation of the first feeder device 140 and second feeder device 142. Alternatively, the actuation mechanism for the carriage 106 may move the carriage 106 along a reciprocating motion path that causes the carriage 106 to reverse direction at each end thereof. More specifically, at each end of the reciprocating motion, the carriage 106 turns and changes its orientation and begins to move in the reverse displacement direction, while the rotation mechanism maintains the orientation of the first feeder device 140 and second feeder device 142 with respect to each other.
Alternatively, the carriage 106 may include a set of solenoid actuators for moving the first feeder device 140 and second feeder device 142 relative to the carriage 106. Specifically, the carriage 106 includes a first solenoid actuator 150 for the first feeder device 140 and a second solenoid actuator 152 for the second feeder device 142. As shown in FIG. 8A, the carriage 106 is at one end of the reciprocating motion and begins to move from right to left. The solenoid actuators 150, 152 are controlled to lock the feeder devices 140, 142 in the desired orientation where the first feeder device 140 is leading the second feeder device 142 along the right-to-left displacement direction. When the carriage 106 reaches the other end of the reciprocating motion and begins to move from left to right as shown in FIG. 8B, the solenoid actuators 150, 152 unlock and move the feeder devices 140, 142 to the desired orientation for the left-to-right displacement direction. The solenoid actuators 150, 152 then lock the feeder devices 140, 142 in the desired orientation where the first feeder device 140 is leading the second feeder device 142 along the left-to-right displacement direction.
In another embodiment, the knitting machine 100 includes the actuation mechanism for moving the yarn feeder set 120. The yarn feeder set 120 is configured to be moved by the actuation mechanism independently of the carriage 106 which is configured for controlling the reciprocating motion of the knitting needles 104. The actuation mechanism is configured to move the yarn feeder set 120 independently of the carriage 106. The actuation mechanism includes a first servo motor for the first feeder device 140 and a second servo motor for the second feeder device 142. The servo motors are configured to move the feeder devices 140, 142 to the desired orientations according to the displacement directions of the yarn feeder set 120 and lock the feeder devices 140, 142 in the desired orientations.
As described above, the holes 124 are arranged and configured with certain dimensions and geometry so that the yarns 122 do not entangle / twist / cross each other when they are fed to the knitting needles 104 for knitting. Additionally, the first yarn feeder device 140 and second yarn feeder device 142 are arranged at a suitable distance between them. This arrangement is to achieve the angular relationship of the yarns 122 and to maintain the correct feeding angles for all the yarns 122 so that they do not entangle / twist / cross each other.
In some embodiments as shown in FIG. 9A and FIG. 9B, the first yarn feeder device 140 includes a first feeder component 144 and a second feeder component 146. The first feeder component 144 includes one of the two holes 124 and the second feeder component 146 includes the other one of the two holes 124. Preferably, the first feeder component 144 includes the first hole 124 a and the second feeder component 146 includes the second hole 124 b. The second feeder component 146 is rotatably coupled to the first feeder component 144 such that the second feeder component 146 always leads or trails the first feeder component 144 along a displacement direction of the yarn feeder set 120.
In one embodiment, the knitting machine 100 includes the carriage 106 coupled with the yarn feeder set 120 such that they move in tandem with each other. When the carriage 106 is moving along displacement direction from right to left as shown in FIG. 9A, the first yarn feeder device 140 is leading the second yarn feeder device 142. Additionally, the second feeder component 146 is rotated or swung to a first rotated position with respect to the first feeder component 144 so that the second feeder component 146 is trailing the first feeder component 144. The second feeder component 146 is fixed in the first rotated position while the carriage 106 is moving. All of the yarns 122 are tensioned and being pulled from right to left. When the carriage 106 reverses direction and is moving along a reverse displacement direction from left to right as shown in FIG. 9B, the first yarn feeder device 140 is leading the second yarn feeder device 142. Additionally, the second feeder component 146 is rotated or swung to a second rotated position with respect to the first feeder component 144 so that the second feeder component 146 is trailing the first feeder component 144. The second feeder component 146 is fixed in the second rotated position while the carriage 106 is moving. All of the yarns 122 are tensioned and being pulled from left to right. Thus, the first feeder device 140 always leads the second feeder device 142 and the second feeder component 146 always trails the first feeder component 144. However, it will be appreciated that other configurations are similarly possible, such as where the first feeder device 140 always trails the second feeder device 142 and/or the second feeder component 146 always leads the first feeder component 144.
The second feeder component 146 may be rotatably coupled to the first feeder component 144 such that the second feeder component 146 automatically reverses direction at both ends of the reciprocating motion of the carriage 106. More specifically, at both ends of the reciprocating motion, the second feeder component 146 rotates or swings between the first rotated position and second rotated position, and remains fixed in that rotated position as the carriage 106 moves. The carriage 106 may include a suitable mechanism coupled to the second feeder component 146 to facilitate this. For example, this mechanism may include the solenoid actuators and/or servo motors described above.
In another embodiment, the knitting machine 100 includes the actuation mechanism for moving the yarn feeder set 120. The yarn feeder set 120 is configured to be moved by the actuation mechanism independently of the carriage 106 which is configured for controlling the reciprocating motion of the knitting needles 104. The actuation mechanism is configured to move the yarn feeder set 120 independently of the carriage 106. The actuation mechanism includes set of servo motors for moving the first feeder device 140 and second feeder device 142. The servo motors are configured to move the feeder devices 140, 142 to the desired orientations according to the displacement directions of the yarn feeder set 120 and lock the feeder devices 140, 142 in the desired orientations, as have been described above. Additionally, the servo motors are configured to rotate or swing the second feeder component 146 relative to the first feeder component 144 and fix the second feeder component 146 in place while the yarn feeder set 120 moves.
As described above, the holes 124 are arranged and configured with certain dimensions and geometry so that the yarns 122 do not entangle / twist / cross each other when they are fed to the knitting needles 104 for knitting. Additionally, the first yarn feeder device 140, second yarn feeder device 142, first feeder component 144, and second feeder component 146 are arranged at suitable distances between them. This arrangement is to achieve the angular relationship of the yarns 122 and to maintain the correct feeding angles for all the yarns 122 so that they do not entangle / twist / cross each other.
In some embodiments, the yarn feeder set 120 includes a first yarn feeder device, second yarn feeder device, and a third yarn feeder device for yarn plating. The first yarn feeder device includes the first hole 124 a, the second yarn feeder device includes the second hole 124 b, and the third yarn feeder device includes the third hole 124 c. Each of the first to third yarn feeder devices may be in the form of the second yarn feeder device 142 described above. Additionally, the first to third yarn feeder devices are configured to move in tandem with each other by reciprocation of the yarn feeder set 106. It will be appreciated that similar mechanisms as those described above, such as the solenoid actuators and servo motors, may apply similarly or analogously for the first to third yarn feeder devices so that they can cooperatively move in tandem with each other. In particular, the first to third yarn feeder devices are configured to move in appropriate leading / trailing positions while the yarn feeder set 120 reciprocates along the elongated bed 102.
In various embodiments described herein, the knitting machine 100 and/or machine knitting method 200 can be used for knitting a fabric, which can be used to form fabric products such as garments. Particularly, due to the angular relationship of the first to third yarns 122, each plated yarn loop includes the third yarn 122 c interposed between the first yarn 122 a and second yarn 122 b. FIG. 10A shows the cross-sectional arrangement of the yarns 122 when the knitting needle 104, specifically a latch needle 104, is extending outwards. FIG. 10B shows the cross-sectional arrangement of the yarns 122 when the knitting needle 104 is retracting inwards.
The first yarn 122 a, which is positioned furthest from the head of the knitting needle 104, appears on the front side of the knitted fabric as a front yarn or main yarn. The front side may be referred to as the technical face which is the side that faces outwards away from a wearer of a garment made from this knitted fabric. The second yarn 122 b, which is positioned nearest to the head of the knitting needle 104, appears on the back side of the knitted fabric as a back yarn or back plated yarn. The back side may be referred to as the technical back which is the side that faces inwards to the wearer. The third yarn 122 c, which is positioned between the first yarn 122 a and second yarn 122 b, forms a mid yarn of the knitted fabric. The yarn feeder set 120 and holes 124 are appropriately arranged so that the yarns 122 can be repetitively engaged / disengaged by the knitting needles 104 without becoming entangled. This prevents the knitting machine 100 from easily becoming jammed or malfunctioning, allowing the fabric to be knitted with all three yarns 122 efficiently.
Therefore, fabric products such as garments can be formed using the knitting machine 100 and/or machine knitting method 200. The fabric products have a knitted fabric material formed from at least three different yarn materials in a layered or plated structure arrangement. Various yarn materials may be used to achieve various functionalities / properties for the fabric products. Non-limiting examples of such yarn materials and/or desired functionalities / properties are listed below.

1. Impact / shock absorbent protective properties;
2. Hydrophobic and hydrophilic yarns to obtain superior wicking and drying properties, respectively;
3. Superior elasticity / stretchability properties;
4. Different properties on the technical face and technical back of the fabric material;
5. Insulation properties, such as thermal insulation;
6. Microencapsulated yarns for slow releasing of a particular substance, such as a scent;
7. Active heating layer hidden in the sandwiched third yarn 122 c; and
8. Anti-bacterial layer hidden in the sandwiched third yarn 122 c.

In some embodiments, the elongated bed 102 is has a front flatbed section and a back flatbed section. During knitting of the fabric, a spacer or inlay may be placed between the front and back flatbed sections so that the plated yarn loops are formed on both sides of the spacer. Particularly, because three yarns 122 are fed by the yarn feeder set to the front and back flatbed sections, the three yarns 122 are formed on each side of the spacer. The knitted fabric including the spacer thus has a total of seven layers, three layers on the technical face, three layers on the technical back, and the spacer layer. It will be appreciated that additional layers can be formed by placing one or more additional spacers / inlays.
In the foregoing detailed description, embodiments of the present disclosure in relation to a knitting machine and a machine knitting method are described with reference to the provided figures. The description of the various embodiments herein is not intended to call out or be limited only to specific or particular representations of the present disclosure, but merely to illustrate non-limiting examples of the present disclosure. The present disclosure serves to address at least one of the mentioned problems and issues associated with the prior art. Although only some embodiments of the present disclosure are disclosed herein, it will be apparent to a person having ordinary skill in the art in view of this disclosure that a variety of changes and/or modifications can be made to the disclosed embodiments without departing from the scope of the present disclosure. Therefore, the scope of the disclosure as well as the scope of the following claims is not limited to embodiments described herein.

Claims

1. A knitting machine for knitting a fabric by yarn plating, the knitting machine comprising:

an elongated bed;

a plurality of knitting needles arranged along the bed, each knitting needle configured for reciprocating motion; and

a yarn feeder set configured for reciprocating motion along the bed and for feeding yarns to the knitting needles, the yarn feeder set comprising:

a first hole for feeding a first yarn at a first angle with respect to the bed;

a second hole for feeding a second yarn at a second angle with respect to the bed, the second angle greater than the first angle; and

a third hole for feeding a third yarn at a third angle with respect to the bed, the third angle greater than the second angle,

wherein the reciprocating motion of the knitting needles repetitively engage and disengage the first to third yarns collectively to thereby form plated yarn loops on the fabric, each plated yarn loop comprising the third yarn interposed between the first and second yarns.

2. The knitting machine according to the claim 1, the yarn feeder set comprising a sole yarn feeder device comprising the first to third holes.

3. The knitting machine according to the claim 2, wherein the sole yarn feeder device is configured such that at least one of the first to third holes is positionally adjustable.

4. The knitting machine according to the claim 2, wherein the sole yarn feeder device comprises:

a sleeve structure for receiving the first to third yarns therethrough; and

a plurality of peripheral structures arranged with the sleeve structure to form the first to third holes.

5. The knitting machine according to the claim 4, wherein at least one of the peripheral structures is moveable along the sleeve structure to positionally adjust at least one of the first to third holes.

6. The knitting machine according to the claim 1, the yarn feeder set comprising:

a first yarn feeder device comprising two of the first to third holes; and

a second yarn feeder device comprising the remaining hole,

wherein the first and second yarn feeder devices are configured to move in tandem with each other such that the first feeder device always leads or trails the second feeder device along a displacement direction of the yarn feeder set.

7. The knitting machine according to the claim 6, further comprising a set of solenoid actuators and/or servo motors for moving the first feeder device and second feeder device such that the first feeder device always leads or trails the second feeder device along the displacement direction of the yarn feeder set.

8. The knitting machine according to the claim 6, wherein the first yarn feeder device comprises the first and second holes and the second yarn feeder device comprises the third hole.

9. The knitting machine according to claim 6, the second yarn feeder device comprising:

a first feeder component comprising the one of the two holes; and

a second feeder component comprising the other one of the two holes,

wherein the second feeder component is rotatably coupled to the first feeder component such that the second feeder component always leads or trails the first feeder component along a displacement direction of the yarn feeder set.

10. The knitting machine according to the claim 1, the yarn feeder set comprising:

a first yarn feeder device comprising the first hole;

a second yarn feeder device comprising the second hole; and

a third yarn feeder device comprising the third hole,

wherein the first to third yarn feeder devices are configured to move in tandem with each other.

11. A method for machine knitting a fabric by yarn plating, the method comprising:

arranging a plurality of knitting needles along an elongated bed;

reciprocating a yarn feeder set for feeding yarns to the knitting needles, the yarn feeder set comprising a first hole, a second hole, and a third hole;

feeding a first yarn through the first hole at a first angle with respect to the bed;

feeding a second yarn through the second hole at a second angle with respect to the bed, the second angle greater than the first angle;

feeding a third yarn through the third hole at a third angle with respect to the bed, the third angle greater than the second angle;

reciprocating the knitting needles to repetitively engage and disengage the first to third yarns collectively; and

forming plated yarn loops on the fabric by the repetitive engagement and disengagement of the first to third yarns collectively, each plated yarn loop comprising the third yarn interposed between the first and second yarns.

12. The method according to the claim 11, the yarn feeder set comprising a sole yarn feeder device comprising the first to third holes.

13. The method according to the claim 11, the yarn feeder set comprising:

a first yarn feeder device comprising two of the first to third holes; and

a second yarn feeder device comprising the remaining hole,

14. The method according to claim 13, the second yarn feeder device comprising:

a first feeder component comprising the one of the two holes; and

a second feeder component comprising the other one of the two holes,

15. The method according to the claim 11, the yarn feeder set comprising:

a first yarn feeder device comprising the first hole;

a second yarn feeder device comprising the second hole; and

a third yarn feeder device comprising the third hole,

16. A yarn feeder device for yarn plating, the yarn feeder device comprising:

a body structure;

a first hole formed on the body structure for feeding a first yarn;

a second hole formed on the body structure for feeding a second yarn; and

a third hole formed on the body structure for feeding a third yarn.

17. The yarn feeder device according to the claim 16, comprising:

a sleeve structure for receiving the first to third yarns therethrough; and a plurality of peripheral structures arranged with the sleeve structure to form the first to third holes.

18. The yarn feeder device according to the claim 17, wherein at least one of the peripheral structures is moveable along the sleeve structure to positionally adjust at least one of the first to third holes.

19. A fabric product formed by a method for machine knitting by yarn plating, the method comprising:

arranging a plurality of knitting needles along an elongated bed;

reciprocating a yarn feeder set comprising a first hole, a second hole, and a third hole;

forming plated yarn loops on the fabric product by the repetitive engagement and disengagement of the first to third yarns collectively,

wherein the fabric product comprises a network of the plated yarn loops, each plated yarn loop comprising the third yarn interposed between the first and second yarns.

20. The fabric product according to the claim 19, further comprising a spacer, wherein each side of the spacer comprises the first to third yarns.