Patent Application
20190003090
Various types of knitting machines are well known. Circular knitting machines, flat knitting machines and warp knitting machines belong to the most important types of these machines.
Knitting machines usually comprise at least one needle bed for supporting knitting tools. Needle beds of circular knitting machines are often called “cylinder” because of their cylindrical shape. In the present publication the impression “needle bed” refers to all kinds of devices that support knitting tools no matter if they are flat, cylindrical or whatever.
Knitting tools are for example needles, sinkers or the like. Knitting tools are parts of knitting machines that are directly involved in the loop forming process and hereby have contact to threads. The different knitting tools grasp, lead or hold down the threads. In the present publication all knitting tools are called “system components”.
One kind of special system components are slider needles. The publication DE 698 03 142 T2 shows a slider needle. The respective slider's profile is u-shaped in the plane perpendicular to the slider's movement. As a result, the two legs of the u-shaped sliders partially embrace the shank of the needle on which the respective slider is moved. One could also say that any leg of the sliders is partially arranged between the needle shank of the needle on which the respective slider slides and the adjacent needle or the adjacent needle shank. During the knitting process there are relative movements between the needle shank and the slider. Hereby, the slider temporarily closes the opening for the thread inside the hook or carries the loop along the needle shank. In doing so the slider gets regularly in contact with the thread.
During knitting the various types of system components acting in different types of knitting machines have relative movements to at least one kind of needle bed. These relative movements in channels of the needle bed generate some problems which are inherent in most modern knitting machines:
High frictional load between system components and needle bed or even sticking of the system components in the channels. The friction causes wear on system components and needle bed and generates undesirable heat in the knitting machine.
In publication DE 10 2013 104 189 A1 the problem of sticking of sinkers in the channels caused by the not longitudinal components of the actuation of the sinkers' butt is discussed. This publication proposes to use two sinkers of different length in one common groove to solve that problem.
The publication EP 0 672 770 A1 shows a flat knitting machine for knitting a tubular knitted fabric. One of the shown knitting machines uses two needles in one common groove. The needles are provided with transfer elements as blades. The said publication mentions that a spacer can be necessary to prevent interference between the needles caused by the transfer elements. The spacer itself and its mode of operation are not described in more detail.
The publication DE 33 11 361 A1 shows a knitting machine comprising needles and sinkers for loop-forming that move in the same longitudinal direction. Said knitting machine comprises a first cylinder placed in a lower region of the knitting machine where the needles are supported in channels. The needles used have a very long shank so that the hook is always far outside the needle cylinder in an upward direction. On top of the needle cylinder there is an additional cylinder for supporting the sinkers and the sinkers are short compared to the needles. The aforementioned long shanks of the needles are on top of the trick walls of the channels of the cylinder for the sinkers and therefore between the sinkers. The means for loop-forming of the needles and the sinkers (hook, holding-down-edge and knock-over-edge) commonly extend in a region of the knitting machine where loops are formed. Said region is located upside of the cylinder of the sinkers. The needles and the sinkers are hereby at least partially separately guided in channels and thus the friction is reduced compared to an arrangement in which needles and sinkers are solely guided in common channels.
The application DE 197 40 985 A1 shows recesses on the flat sides of knitting needles or on the walls of channels of a needle bed. The recesses are only provided in certain regions of the side faces of the knitting needles and not on the full length of the side faces of the needles. As a result of these measures, the surface area of the contacting surfaces of the said elements of the knitting process is reduced. Thus the energy consumption and the heat generation in the machine are reduced.
The application EP1860219A1 shows knitting needles with a relatively thin shank. Some of the figures of this publication show in a cross-sectional view that the needles are arranged askew or diagonally in the needle grooves so that only one of the two top corners and the opposing bottom corner of the needles' cross section touch the needle groove. The surface area of the contacting surfaces is once again reduced so that the energy consumption of the system decreases. The heat generation is thus also reduced.
There are other patent publications which show knitting machines in which the side faces of the shanks of adjacent needles are in contact with each other (“side-by-side needles”):
The application WO2012055591A1 shows a knitting machine which was constructed for the following purposes: High gauge, low manufacturing costs and low energy consumption. This publication also shows groups of two needles which are in contact to each other during the knitting process (side-by-side needles):
Application WO2013041380A1 shows a knitting machine with improved actuation cams for the type of side by side needles shown by the aforementioned WO2012055591A1. The knitting machines can be manufactured at lower costs and they can produce high quality fabrics. However the publication's teaching has the same drawbacks as mentioned before.
It is the object of the present invention to provide a process and a device for the forming of loops with a reduced energy consumption and heat generation of the knitting machine.
The above object is achieved with the method according to claim 1, the device according to claim 3 and the system component according to claim 14.
In most loop-forming processes—including inventive ones—a plurality of needles will be used for forming the respective loops. Usually, there are more than hundred needles involved in a typical loop forming process. One characteristic of the inventive loop forming process is that there is at least one groove which is provided with at least two system components. There can be 2, 3, 4, 5, 6 or even more of these system components in one groove. In the present publication the phrase “system components” means textile tools which are provided with loop forming means like hooks or latches which are in contact with the yarn (or also called threads) and which actively take part in the loop forming process. Therefore the loop-forming means are preferably involved in the forming of loops at least for a period of time during the loop-forming process. Usually such system components are called needles or sinkers.
The inventive method uses a so-called spacer or spacing means in order to adjust the distance between the loop forming means of two adjacent system components which are moved or housed in one groove. Therefore the word “spacer” is a functional expression which denotes an additional part as well as an integral part which is made of one piece preferably with the respective system component's shank.
The spacer, however, does not take part in or abstains from the loop forming process. In most cases the distance between the loop forming means of two adjacent system components is a distance in the second direction (x) which corresponds to the direction of the width of the grooves. The person-skilled in the art will understand that this second direction could have a purely linear character if flat knitting machines are concerned. The movements of system parts of circular knitting machines can—however—be described with cylinder coordinates (r, φ, z). Therefore the direction of the width of the grooves of the channels has circular components (φ). However, the direction of the width of the grooves of all knitting machine types shall be denoted with “x” in the present publication.
As already mentioned, the space between the loop forming means of the two adjacent system components is free of loop forming means which belong to or are actuated by system components of the same grove or even of the same needle bed. As a consequence, the distance which is adjusted by the spacers or by means of the spacers is the width—or the extension in the second direction (x)—of the aforementioned free space between the loop forming means of two adjacent system components of one needle bed. No loop forming means which is actuated by or part of a system component which is moved or housed in the same groove—or expressed in a wider way—which is housed in the same (first) needle bed interferes in this space. On the other hand, loop forming means of other grooves—or broader—another second needle bed which is directed differently may interfere there and cooperate with the loop forming means of the first needle bed so as to form loops. Example: the first needle bed houses knitting needles. The second needle bed houses sinkers which interfere in this space in order to hold down the previously formed loops so that the needles can form new loops.
However, the distance adjusted by the spacers is free of system components of the same groove or the same needle bed, so that the above definition still applies. Usually the grooves of the first and the second needle bed need to have a different direction so that the system components of the second needle bed or its grooves can cooperate in the way described above. Therefore another definition of the “distance” of the space defined by this distance could say, that there are no loop-forming means in this space or area of the loop forming zone, in which loop forming means which are moved in the same direction reach into.
The aforementioned spacer is moved together with at least one of said two adjacent system components. “Moved together” means in the present context that the relative velocity between the spacer and the respective at least one system component is nil. It is possible to actively move the spacer this way, however, it is also possible to in any way connect these two elements (spacer and system component) so that they will not move with respect to each other. The respective connection can transfer power between the spacer and the system component. Most advantageously the connection can sustain the amount of power necessary for the movement either of spacer or of the respective system component. The respective connection can be made in several ways and the connection can be adjusted so as to sustain different amounts of power. Another definition for this point could be that the spacer is not relocatable or immovable with regard to the system component with which it is connected. The spacer could also be part of and integral with said system component.
The spacer and the respective first system component with which it moves is at least temporarily moved inside a section of the groove in which the spacer and the second of the two adjacent components are in mechanical contact with each other. Most advantageously the length of the section or the sections in which the spacer and the second of the two adjacent components and/or the spacer of the second system component are in mechanical contact with each other is equal to 70, 80, 90 or 95% of the system component's length. There are further advantages if the spacers and the system components are the only components moved in the groove on the respective sections of the groove. A different approach is to provide the side surfaces of system components with a plurality of spots or areas which adjust the distance between the system components (for the purposes of the present publication this plurality of spots or areas is also called “spacer”). Such a group consists of at least two and—more advantageously—of at least three members. Therefore these spots are “elevated” with regard to the side surfaces in the x-direction. In this case it is advantageous if the distance between the two spots which are provided with the biggest distance of said plurality of spots (in y-direction) of one side surface is at least equal to 50, 60, 70, 80, 90 or 95% of the system component's length. Embodiments which have spots or areas of the kind described above on one system component should be provided with a smooth and/or even side surface on the adjacent side of the other adjacent system component. It is also advantageous if the thickness of the spacer (or the plurality of spots or areas of course) is even or slightly bigger than the thickness of the respective knitting component. The thickness means in the present context the spacer's extension in x-direction. Additional advantages arise if the extension of the spacer in z-direction (the height of the spacer) equals at least 50, 60, 70, 80, 90% of the height of the system component's shaft. Most advantageously the heights of the spacer (or the group of spots or areas) and the shaft of the system components on which the spacer is fixed are equal. It is advantageous if the two adjacent system components are knitting needles. It is also advantageous—especially for the knitting device and knitting process—if the two adjacent system components are provided with butts which slide through the same cam tracks during the knitting process. It is also advantageous if the spots or areas are welded on the shaft. If the spacer consists of a group of spots or areas it is also advantageous if the distance between the beginning of the first and the end of the last spot or area in y-direction equals at least 50, 60, 70, 80, 90 or 95% of the system component's length (length once again in y-direction).
Another approach is to provide both adjacent system components with the respective spots or areas. In this case, the spots or areas are either situated in different segments of the longitudinal extension of the two system components or the areas are provided with an even side surface so that the system components can still move with regard to each other when the side surfaces touch each other or are in mechanical contact with each other.
In other embodiments there are two spacers which are situated between the two adjacent system components. The first spacer is connected with the first of the two system components and the second spacer with the second of the two system components. In this case the spacers could be in mechanical contact with each other. However, depending on the position and the shape of the spacers, that at least one spacer could also be in mechanical contact with the other system component with which it is not connected and/or with the other spacer.
Needle beds which have a plurality of grooves which are parallel to each other are advantageous. Most of the time “temporarily” means at least during a period of time during the loop forming process.
Usually, the distance between the loop forming means of two adjacent system components of one groove should be in relation with the gauge of the respective knitting machine. It should be at least half of the width of the loop forming means of the system components or even better it should be the full width of these loop forming means. In most state-of-the-art knitting machines the system components perform periodic movements in the longitudinal direction which are caused by the relative movement of the respective needle bed with regard to cam holders: The system components and spacers which are inserted in the grooves of a needle bed are provided with butts. These butts protrude out of the needle bed. The aforementioned relative movement of the needle bed with regard to a cam holder forces the butts to move along a cam track which is formed by the cams. This movement provides for the force for the movements of the system components and spacers in their respective grooves. Circular knitting machines are usually provided with cam holders which are fixed on the machine frame. Flat knitting machines often use cam holders which are part of carriages which are moved with regard to the needle bed. In both cases there is a relative movement between cam holders and needle beds.
It is advantageous if the loop forming means of adjacent system components of one needle bed perform their movements and therefore reach their extrema in their longitudinal direction with a certain delay. Once again this delay corresponds to the mechanical distance of the loop forming means of these two adjacent system components. Most advantageously this distance—and therefore the respective delay—is related with the gauge. Therefore, the distance between the loop forming means of two adjacent system components which is adjusted by means of the spacer should be in the range between half of the width of the system component's loop forming means and their full width.
In the present publication the phrase “first velocity (vk)”denotes the relative velocity between the needle bed and the machine frame which carries the cams. The system components of the needle bed usually perform periodic movements in the longitudinal direction (y). These movements resemble harmonic functions and the system components reach minima and maxima (extrema) of their longitudinal position during these movements. It is advantageous if two adjacent system components reach their extrema with a delay of time. In embodiments with a good performance this delay should be bigger than half of a first quotient or more advantageously equal to said first quotient. Said first quotient is the quotient of the distance between the loop forming means of the two adjacent system components in the second direction and the first velocity. Especially in loop forming methods with a high velocity it is advantageous if said delay is equal to the quotient. One could also say that very preferred embodiments have the same distances between the cam track extrema of adjacent system components so that the whole loop forming device is provided with the same pitch (see below).
Another property is the distance between the loop-forming means in x-direction which is adjusted by the at least one spacer: It is in the same range or approximately the same as the width of the needle component's shanks. The range can start with 0.7 times the width of the shank. It is however advantageous if the respective factor is 0.9 or 1.
Embodiments in which the two system components are provided with only one spacer which is immovably connected with one of said two adjacent system components have the following benefit:
If there are two spacers between the two adjacent system components of one groove the distance can be built up by the two spacers in different ways.
It is advantageous if the distance in the second direction between the loop forming means of the at least two system components is equal to at least one distance between the loop forming means of two other adjacent system components of the needle bed in the second direction, whereby these two other system components are separated by an immovable wall of a groove of a needle bed. This means that all distances between adjacent system components' loop forming means of a needle bed can be equal. There can be other parts of the needle bed or of the system components which contribute to the distances no matter if the distances are primarily adjusted by the spacers or by the immovable walls of the grooves.
A system component which is connected with the spacer can be manufactured out of the same piece as the spacer. The “spacer” can also be a bend (or a plurality of bends) of the shank of the system component with which it is connected. In this context the “bend” is any kind of a deviation from an even extension of the shank in its longitudinal direction. Most of the time a shank with such bends would show a meandering or a zigzag pattern in the x-y plain. In other words each bend may comprise a portion of the shank of the system component with which it is connected. This portion is offset in the x-direction relative to the even extension of the system component's shank.
In the cases described it is advantageous if there are side surfaces of the system components of such system components which are directed towards the adjacent system component, which are even, and which are parallel to the next immovable wall of a groove of the respective needle bed. These surfaces could also be parallel to the side surface of the neighboring shank.
Instead of being integral with the shank the spacer could consist of an additional part which has been connected in a mating process with a system component. In this case it is easier to provide the spacer with materials which are not present in the system components. Examples: the shank of the system components can be a relatively conventional one, which means it can be a punched metal part. The additional part could possess a side surface of graphite which would decrease friction with the adjacent system component of the respective spacer. There are different mating processes which could have its advantages in the present context. The phrase “material” means in the present context that different elements and mixtures of elements can be used to manufacture system components and the respective spacer. Additionally and alternatively this phrase can mean that a spacer and the respective system component is manufactured with a different manufacturing method. These methods can include the use of plastics or other synthetic material for forming parts of the system components or above all the spacer.
System components which can be used with benefit in the present context possess a butt with a width which is smaller than the maximum combined extension of the shank and the spacer(s) with which the respective system component is immovably connected in the same second direction (x). The maximum combined extension is the maximum distance of the side surfaces of the spacer and the respective system component which are directed in opposite directions. The butt of a system component extends in the third direction which corresponds to the height direction of the shank and overtowers the shank. Moreover, the butt has its extension in the other two directions. Preferable butts have a front part with a width which is smaller than the width of their middle part. This is to say the butts could also be wedge-shaped.
Further characteristics and advantages of the invention will become better apparent from the description of the figures. The figures show preferred but not exclusive embodiments of the invention and therefore provide non limiting examples. Most of the individual features shown can be used with advantages for improving the present invention in its broadest form.
A further aspect of the present invention is the shape and the symmetry of the system units used. In the language of the present publication the term “system unit” means a group of members or elements which are moved together during the loop forming process. In the present publication there are system units disclosed which consist of one spacer and one system component like a needle. There are other system units which consist of two spacers located on the two side surfaces of the system component with which they are moved. An interesting point is that the system units which consist of one spacer on one side of the system component are asymmetric with regard to a symmetry line which is parallel to the system components' side surfaces and which passes through the centre of the hook of this system component. Standard system components are symmetric with regard to the aforementioned symmetry line. System units which consist of two spacers which are inmovably placed on the side surfaces of the respective system component can also be symmetrical with regard to the aforementioned symmetry line. As mentioned in the above paragraph it has advantages to provide such a system unit with a butt with a width which is smaller than the width of the system unit. Therefore one could also say that many inventive embodiments are provided either with a symmetrical system unit or with at least one system unit which is provided with two spacers (one on each side surface of the system component).
It has further benefits to shape the end section of the butt in the direction of the hook and/or the end section of the butt in the direction of the rear part of the system component or system unit like a wedge which is to say that the width of the butt decreases in the direction of at least one end of the extension of the butt.
It is advantageous if at least one or even any of the two system components is provided with one functional group of loop forming means. This is to say that the loop forming means of one system component only take part in the simultaneous formation of one loop in the same time period. After this period of time they usually start the formation of a new loop. Examples: the hook and the latch of one (latch) knitting needle form such a functional group. The same applies for the hook and the slider of one (slider) knitting needle. Sinkers are equipped with different so-called edges (holding down edge, knocking over edge etc.), which usually also only take part in the formation of one loop per time period and per sinker. Warp knitting modules which are used for forming several loops and which comprise a plurality of needles and therefore always simultaneously form a plurality of loops do not fall under the above definition for more advantageous system components. It could be even more beneficial if there was just one loop forming means per system component. The loop forming processes and devices for loop forming are advantageous if the two adjacent system components are movable (or are moved in case of the process) with respect to each other.
It is also beneficial if the two adjacent system components take part in the same knitting process during the same period of time (the device is conceived for knitting with the at least two adjacent system components during the same period of time). This means that knitting devices which are provided with different knitting components which are used for knitting different kinds of knitwear in different time periods like the device shown in EP 0 672 770 A1 do not fall under the above definition. It is also advantageous if the term “the spacer adjusts the distance between the loop forming means” means that there are no additional spacing means between the system components. However, the person skilled in the art will understand, that there is often additionally a small gap between the system components which is either filled with air or sliding means like oil (or both). Moreover, it is advantageous if the spacer really determines the aforementioned distance between the loop forming means of the two adjacent system components. This is to say that the flexibility of the spacer has its limits: thin blades as the ones used for transfer elements (see once again EP 0 672 770 A1) are in this context not very beneficial. Advantageous spacers are not transfer elements (usually transfer elements take part in the transfer of the loop between two different system components, usually of two different needle beds). It is also advantageous if the inventive device is not provided with an immovable wall between the two adjacent system components. The same applies with regard to movable elements like a movable spacer: it is advantageous if no such element is placed between the at least two adjacent system components of the present invention (one could also say that the space between two adjacent system components is free of such elements).
The embodiments of the system components which are shown in
The spacers 10 move together with the system components 11, 12. They are mated with them with splints 44 which are symbolized by the dotted lines 44. The spacers 10 are also devoid of loop forming means like hooks 20 and latches 24 and the like and do not take part in the loop-forming process. Moreover, the spacers essentially define the distance between two neighboring or adjacent system components 11, 12 and their loop-forming components 20, 24. Most of the time the sinkers 25 and the respective system components 11, 12 still have a certain distance, so that the distance between these system components 11, 12 is the sum of these distances and the sinkers' 25 width. The areas of the loop-forming zone 19 which are situated between the loop-forming means 20, 24 of the system components 20, 24 of the first needle bed 14 are free from loop forming means which are part of or actuated by loop forming means of this needle bed. The loop forming means of the sinkers 25 are part of the sinkers which are moved in the grooves of another needle bed. The grooves of individual needle beds 14 are usually parallel to each other.
Most advantageously the immovable walls 15 and/or the shanks 39 of the system components 11, 12 and/or the spacers 10 have the correct width corresponding with the gauge of the respective needle bed 14. In some advantageous embodiments the width of immovable walls 15 and/or the shanks 39 of the system components 11, 12 and/or the spacers 10 is (nearly) equal.
The above passages partly deal with the distance 21 between the loop forming means 11, 12 of one groove. In cases, in which a system component is provided with several loop-forming means—like the hooks 20 and latches 24—it is advantageous to say that the width of these loop forming means is equal with their broadest extension in the second direction x: As a result, the latch needles of
On the other hand
The line 53 is a symmetry line which is directed in the longitudinal direction y parallel to the side surfaces of the needles' shanks 39 and which crosses the centre of the needles' hook 20.
| Number | Date | Country | Kind |
|---|---|---|---|
| 15179093.8 | Jul 2015 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/067914 | 7/27/2016 | WO | 00 |
