U.S. patent application number 15/748918 was filed with the patent office on 2019-01-03 for loop-forming method, device and system component.
The applicant listed for this patent is Groz-Beckert KG, Santoni S.P.A. Invention is credited to Marco Andreoli, Stefano Rizzi, Martin Wornle.
Application Number | 20190003090 15/748918 |
Document ID | / |
Family ID | 53761288 |
Filed Date | 2019-01-03 |
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United States Patent
Application |
20190003090 |
Kind Code |
A1 |
Wornle; Martin ; et
al. |
January 3, 2019 |
Loop-Forming Method, Device and System Component
Abstract
A loop-forming process includes moving at least two system
components (11, 12) in one groove (16) of a needle bed in a first
longitudinal direction (y). The system components contact threads
(23) for forming loops. At least one spacer (10) is placed between
two adjacent system components (11, 12) moved in the groove (16),
whereby this spacer (10) contributes to distance (21) adjustment
between loop-forming portions in the direction (.chi.) of the
grooves' (16) width. The at least one spacer (10) moves together
with a first one of the two adjacent system components (11, 12) and
is at least temporarily moved inside a section (41) of the
longitudinal (y) extension where the spacer (10) and the second
system component (12) are in mechanical contact and/or in which the
spacer (10) is in mechanical contact with a second spacer (10)
moved together with the second of the two system components (11,
12).
Inventors: |
Wornle; Martin; (Mossingen,
DE) ; Andreoli; Marco; (Castegnato Brescia, IT)
; Rizzi; Stefano; (Brescia, IT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Groz-Beckert KG
Santoni S.P.A |
Albstadt
Brescia |
|
DE
IT |
|
|
Family ID: |
53761288 |
Appl. No.: |
15/748918 |
Filed: |
July 27, 2016 |
PCT Filed: |
July 27, 2016 |
PCT NO: |
PCT/EP2016/067914 |
371 Date: |
January 30, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 35/04 20130101;
D04B 15/14 20130101; D04B 15/06 20130101; D04B 15/10 20130101; D04B
35/02 20130101 |
International
Class: |
D04B 35/04 20060101
D04B035/04; D04B 15/06 20060101 D04B015/06; D04B 15/10 20060101
D04B015/10 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 30, 2015 |
EP |
15179093.8 |
Claims
1. Loop-forming process, comprising: moving at least two system
components (11, 12) in one groove (16) of a needle bed relative to
said needle bed (14) in a first direction (y) which corresponds to
longitudinal direction, said system components (11, 12) contacting
threads (23) for forming loops with their loop-forming portions
(20, 24), contributing to adjusting a distance (21) between the
loop-forming portions (20, 24) with at least one spacer (10) placed
between two adjacent system components (11, 12) of the system
components, the distance adjusted in a second direction (x) which
corresponds to a direction of a width of the grooves (16) of the
needle bed (14), whereby said at least one spacer (10) abstains
from the loop-forming process, moving the at least one spacer (10)
together with a first one of said two adjacent system components
(11, 12), at least temporarily moving the at least one spacer (10)
inside a section (41) of the longitudinal (y) extension of the
groove (16), wherein one or both of: a first spacer of the at least
one spacer (10) and a second one of said two adjacent system
components (12) are in mechanical contact with each other, and the
first spacer (10) is in mechanical contact with a second spacer
(10) of the at least one spacer which is moved together with the
second one (12) of said two adjacent system components (11,
12).
2. Loop-forming process according to claim 1 further comprising:
moving the needle bed (14) relative to a cam holder of the knitting
machine with a first velocity (vk), so that butts (17) of the
system components (11, 12) pass through cams (18) connected with a
cam holder of the loop-forming machine, whereby the butts (17)
receive force for movement of the system components (11, 12), the
system components (11, 12) performing periodic movements in their
longitudinal direction (y) and that the system components (11, 12)
reach minima and maxima during these movements, the loop-forming
portions (20, 24) of a first adjacent system component (11) and a
second adjacent system component (12) of the two adjacent system
components reaching minima and maxima (37) of their movements with
a delay of time bigger than half of a first quotient or equal to
said first quotient, whereby the first quotient is a quotient of a
distance (21) between the loop-forming portions of the two adjacent
system components in the second direction (x) and the first
velocity (vk).
3. Device for loop-forming, comprising: a needle bed, a plurality
of system components (11, 12) comprising loop-forming portions (20,
24) and configured to be involved in loop-forming at least for a
period of time during a loop forming process, the needle bed (14)
is provided with a plurality of grooves (16) which have an
extension in a first direction (y) which corresponds to a
longitudinal direction (y) of the system components (11, 12),
whereby said system components (11, 12) are movably arranged in
said grooves (16) and individual grooves house at least two system
components (11, 12), at least one spacer (10) configured to
contribute to adjustment of distance (21) between the loop-forming
portions (24) of two adjacent system components (11, 12) of the
plurality of system components of one of the grooves (16) in a
second direction (x) which corresponds to a direction of width of
the grooves (16) of the needle bed (14), wherein a first spacer of
the at least one spacer (10) is immovably connected with at least a
first one of said two adjacent system components (11, 12) at a
position of the longitudinal extension (y) of the system components
(11, 12) which is during the loop-forming process at least
temporarily housed by a section of one of the grooves (16), wherein
one or both of: the first spacer (10) and a second one (12) of the
adjacent system components (12) are in mechanical contact with each
other, and the first spacer (10) is in mechanical contact with a
second spacer (10) of the at least one spacer which is immovably
connected with the second one of said two adjacent system
components (12).
4. Device for loop-forming according to claim 3 wherein a first one
of the two adjacent system components (11, 12) is provided with and
immovable connected to one of the at least one spacer (10).
5. Device for loop-forming according to claim 3 wherein the two
system components (11, 12) are provided with two spacers (10) of
the at least one spacer, and a first of the two spacers (10) is
immovably connected with the first (11) of said two adjacent system
components and a second of the two spacers (10) is immovably
connected with the second (12) of said two adjacent system
components.
6. Device for loop-forming according to claim 3, wherein the
distance (21) in the second direction (x) between the loop-forming
portions (20, 24) of the two system components (11, 12) of one
groove (16) is equal to at least one distance between the
loop-forming portions of two other adjacent system components of
the needle bed (14) in the second direction (x), whereby the two
other adjacent system components (11, 12) are separated by an
immovable wall (15) of a groove (16) of a needle bed (14).
7. Device for loop-forming according to claim 3, wherein the
distance in the second direction (x) which is adjusted by the at
least one spacer (10) between the loop-forming portions (20, 24) of
the two system components (11, 12) is approximately equal to a
width of a shank (39) in the second direction (x) of at least one
of the two adjacent system components (11, 12).
8. Device for loop-forming according to claim 3, wherein the at
least one spacer (10) is integral with the system component (11,
12) with which the at least one spacer (10) is immovably
connected.
9. Device for loop-forming according to claim 3 wherein the at
least one spacer (10) comprises a bend (51) of a shank (39) of the
first one of the two adjacent system components (11, 12) with which
it is immovably connected.
10. Device for loop-forming according to claim 3 wherein the at
least one spacer (10) comprises a bend (51) of a shank (39) of the
first one of the two adjacent system components (11, 12) with which
it is immovably connected and that at least a section of the bend's
(51) side surface which is directed towards the second one of the
adjacent system components (11, 12) is parallel to a surface of an
immovable wall (15) of the groove (16) in which the respective
system components (11, 12) are housed.
11. Device for loop-forming according to claim 3 wherein the at
least one spacer (10) is an additional part (38) connected in a
mating process with the one of the two adjacent system components
(11, 12) with which it is immovably connected.
12. Device for loop-forming according to claim 11 wherein the at
least one additional part (38) comprises materials which are not
included in the system component (11, 12).
13. Device for loop-forming according to claim 12 wherein the
additional part is connected to the system component (11, 12) with
which the spacer (10) is connected by at least one of: splice, weld
joint (42), solder joint, splint (44), or combinations thereof.
14. System component for loop forming which comprises: a shank (39)
configured to glide in a needle groove (16) of a needle bed (14)
which essentially extends in a first longitudinal direction (y) and
has a width in a second direction (x), means for loop forming (20,
24) which are placed on one longitudinal end of the shank (39), a
butt (17) configured to interact with a cam (18) of a knitting
machine, whereby the butt (17) has an extension in a third
direction (z) which corresponds to a height direction (z) of the
shank and overtowers the shank (39), a spacer (10) which is placed
immovably on the shank (39) wherein a width of the butt (17) in the
second direction (x) is smaller than a maximum combined extension
of the shank (39) and the spacer (10) in the second direction (x)
at at least one position of an extension (45) of the butt (17) in
the first direction (y).
15. System component for loop forming according to claim 14 wherein
the butt (17) has a first width (46) in the second direction (x) in
an end section (43) of its extension (45) in the first direction
(y), the butt has a second width (47) in the second direction (x)
in at least one middle section (49) of its extension (45) in the
first direction, and the second width (47) is bigger than the first
width (46).
Description
[0001] 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.
[0002] 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.
[0003] 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".
[0004] 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.
[0005] 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:
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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"): [0013] The
DE610511B discloses two very similar types of needles. Both types
comprise a thick (in the direction of the width of the needles) and
stable rear part which carries the needle butts. The difference
between the two needle types is that the first group is provided
with a longer rear part than the other type. [0014] The front parts
of both types of needles, which support the hook, are relatively
thin. [0015] The front parts have the same length. [0016] In the
needle beds shown by this publication a segment of the thin front
part of each of the needles is guided in a respective slot of the
needle bed. Needles of the long type surround groups of needles of
the short type. An end segment of the rear part of the long needles
is additionally guided by respective slots. The side faces of
segments of the thicker rear parts of adjacent needles are in
contact with each other. [0017] The DE610511B aims at reducing the
costs for grinding the common long needle channels of the needle
bed: These long channels are replaced by the above mentioned slots
which only cover relatively small segments of the length of the
needles. However, this publication fails to teach a knitting device
which is apt to the requirements of modern knitting processes: If
the knitting beds shown in the DE610511B were subject to modern
knitting velocities the needles would be bent. Therefore the
needles would become subject to undue wear or the needles would
even stick in the respective slot.
[0018] 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): [0019] The rear
part of these needles is placed in a joint needle channel so that
segments of the side faces of these needles have contact with each
other. In its front part this needle channel is bifurcated so that
the front parts of the two needles of a needle bed are spaced away
from each other. As a result, the front part of each needle is bent
during its movements in its length direction. This fact causes wear
and energy consumption. Moreover, it is not easy to bend needles
with thick shanks.
[0020] 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.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] 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, .phi., z). Therefore the
direction of the width of the grooves of the channels has circular
components (.phi.). However, the direction of the width of the
grooves of all knitting machine types shall be denoted with "x" in
the present publication.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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).
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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).
[0036] 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.
[0037] 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: [0038]
At least one specially shaped system component which is connected
with or which includes the spacer could be the "first system
component", whereas the (at least one) second system component
could be a "standard needle" which is to say a needle which can
belong to the state of the art. The thickness of the specially
shaped needle can be twice or 1.5 times the thickness of the
"standard" needle.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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).
[0047] 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.
[0048] 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.
[0049] 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).
[0050] FIG. 1 shows a perspective view of a first needle bed which
is equipped with first and second system components, each of them
equipped with a spacer with an equal width.
[0051] FIG. 2 shows one of the system components which equip the
first needle bed which is shown in FIG. 1.
[0052] FIG. 3 shows a cross-sectional view of the first and the
second system component in a groove of the first needle bed.
[0053] FIG. 4 shows a perspective view of a second needle bed which
is equipped with first and second system components. The first
system components are equipped with a spacer which adjusts the
whole distance between the loop forming means of two adjacent
system components of one groove.
[0054] FIG. 5 shows a pair of two needles which were extracted from
one groove of the second needle bed and which consist of a first
needle with a spacer and a second needle without one.
[0055] FIG. 6 provides a cross-sectional view of the second needle
bed with one pair of system components.
[0056] FIG. 7 shows a pair of needles consisting of two needles
each one is provided with a spacer which is essentially an
additional part.
[0057] FIG. 8 shows the passage of a cam with two butts of system
components.
[0058] FIG. 9 provides a first symbolic arrangement of cams.
[0059] FIG. 10 shows a plain view of a third needle bed.
[0060] FIG. 11 is a plain view of a forth needle bed which is
provided with a first and a second kind of system components with
bends in its shanks.
[0061] FIG. 12 is a plain view of a fifth needle bed.
[0062] FIG. 13 provides a second symbolic arrangement of cams.
[0063] FIG. 14 provides a plain view of a first groove equipped
with system elements
[0064] FIG. 15 provides a plain view of a second groove equipped
with system elements
[0065] FIG. 16 provides a plain view of a third groove equipped
with system elements
[0066] FIG. 1 shows a needle bed 14 which is provided with grooves
16 which are delimited by immovable walls 15. In the grooves 16 of
this first embodiment of a needle bed 14 there are two system
components 11 and 12. The power for the movement of the system
components is transferred with butts 17 to the system components 11
and 12. Each system component 11, 12 is provided with loop forming
means. In the case shown in FIG. 1 the system components 11 and 12
are latch needles and therefore their loop forming means are hooks
20 and latches 24, which extend in a loop forming zone 19. FIGS. 2
and 3 are about the same embodiment of the needle bed 14 and its
system components 11, 12. FIG. 2 shows a system component 11 of the
kind used in the needle bed 14 of FIG. 1. As said before the system
component 11 is a needle with a butt 17 and a shank 39. The system
component 11 is also provided with a spacer 10 with which it is
immovably connected. In the case shown the spacer 10 and the shank
39 of the system component 11 are of one piece. FIG. 3 shows a
section of the needle bed 14 of FIG. 1 in a cross-sectional view.
In FIG. 3 the distance 21 which is also the distance between the
loop forming means 20, 24 of two adjacent loop forming components
11, 12 of one groove 16 is clearly shown. The line 40 symbolizes
the limitation between spacers 10 and shank 39 which does not
really exist since these two members of the first embodiment are of
one piece. In the first embodiment the first 11 and the second 12
system component are each provided with one spacer 10. These
spacers 10 have the same width so that each of the spacers adjusts
half of the distance 21. As already said before those spacers are
of one piece with the shanks 39 of the system components 11, 12
with which they are immovably connected.
[0067] FIGS. 4, 5 and 6 show a second embodiment of the needle bed
and its respective system components. The only significant
difference between the first and the second embodiment shown in
this publication is that in the second embodiment two adjacent
system components 11, 12 of one groove 16 are only provided with
one spacer 10 which is immovably connected with the first 11 of the
two system components. This means that the whole distance 21
between the loop forming means 20, 24 of the two system components
11, 12 is adjusted only by means of only one spacer 10. This spacer
10 is once again of one piece with the system component with which
it is connected. In both embodiments shown so far one can easily
see that there are segments 41 of the longitudinal extension of the
grooves 16 in which the spacers 10 are housed or moved. An
arbitrary segment of the longitudinal extension of the grooves is
symbolized by the bracket 41. In the first embodiment the two
spacers 10 are in contact with each other when the system
components 11, 12 are moved in the grooves 16. In the second
embodiment only the first system component 11 is provided with a
spacer 10 and the spacer 10 touches the second system component 12
when moved and even when the knitting machine does not work. The
segments 41 of the grooves 16 in which this condition applies (the
spacer 10 touches the adjacent system component 11) are very long
(more than 90% of the system components' length.
[0068] FIG. 7 shows a pair of system components 11, 12 which is
very similar to the pairs of system components 11, 12 which are
housed in the grooves 16 of the first embodiment: Both system
components 11, 12 are immovably connected with one respective
spacer 10. Unlike the needles of the first embodiment the needles
shown in FIG. 7 are not of one piece with their respective spacer
10. Therefore, this spacer 10 is an additional part 38 which is
mated with the shank 39 of the respective system component 11, 12
with several weld points 42. Therefore the line 40 has in FIG. 7 a
very physical significance since it denotes the limitation between
two members 11, 10, or 12, 10. In most cases the joints or
connections of very similar materials could be welt points or welt
lines. Solder points or lines can mate similar or at least slightly
different materials like different metals. In other cases very
different materials can also be used and mated with other
connections like splints or adhesives or the like. One possibility
is to manufacture the shank 39 of the system component 11, 12
presumably of metal and use a material with a very low friction
and/or self-lubricating properties like graphite or Teflon for the
spacer 10.
[0069] The embodiments of the system components which are shown in
FIGS. 1 to 3 (first embodiment) and the system components shown in
FIG. 7 have a butt in common which has a width which is smaller
than the combined (maximum) extension of its spacer 10 and its
shaft 39 in the second direction (x). The same applies with regard
to the first system components 11 according to the second
embodiment which is shown in FIGS. 4 to 6. In contrast to the
embodiment shown directly below the system components of FIGS. 1 to
7 have this smaller width in all sections of their whole
longitudinal extension 45.
[0070] FIG. 8 shows two butts 17 of system components 11, 12 which
pass through the passage 35 of a cam 18. The reason for the butts'
17 passing through the passage 35 is the relative movement vk (see
the respective pointer in FIG. 8) between cam holder and cams on
one side and the needle bed 14 (not shown in FIG. 8) and system
components 11, 12 with their butts 17 on the other side. The cam 18
is not completely shown in FIG. 8. The limitations 48 of the
passage 35 are however shown. They are surrounded by a hatching
which symbolizes parts of the cam 18. The viewer of FIG. 8 can see
the two butts 17 through the passage 35 (the cam holder is for the
viewer transparent) so that invisible parts of the system
components shanks (the parts covered by the cam) have to be shown
with broken lines. Both butts 17 have an extension 45 in the first
direction y. The width 46 of the butts 17 in the end sections 43 is
smaller than their width 47 in their middle sections 49. This
definition does not include end sections of state-of the art butts
with rounded edges or edges which are in any other ways chamfered.
The aforementioned feature (different widths in different sections,
see above) is advantageous with regard to any embodiment of the
present invention. It is however even more advantageous with regard
to embodiments which are equipped with butts which have a maximum
width in the second direction x which is bigger than the extension
of the respective system component's 11, 12 loop forming means 20,
24. In this case, it is advantageous if there are end sections 43
of the butt 17 with a width which is equal to the width of the loop
forming means 20, 24. It is even more advantageous if there are
sections in the middle part which are provided with a width which
is equal to the maximum width of the system component and the
spacer combined (in x direction). In most cases the end sections
will have a somewhat wedge-shaped end. The very end section of the
butts 17 could be rounded.
[0071] FIG. 10 provides a plain view of a needle bed 14 which is
equipped with system components 11, 12 which have the same butts
which are shown in more detail in FIG. 8. Once again a pair of
system components 11 and 12 is housed in one groove 16 which is
delimited by immovable walls 15. The butts of the different system
components are arranged with regard to each other as if they were
passing a passage 35 of a cam 18 as the ones shown in FIG. 9.
[0072] FIG. 9 shows two cams 18. The second one is placed above the
first one. Each of the cams 18 is provided with a passage 35 and a
maximum 37. FIG. 13 also shows two cams being arranged above each
other. The maxima 37 of the two cams 18 are displaced or shifted in
the second direction x with regard to each other. This shift 50 is
a very advantageous possibility to adjust the delay between
adjacent system components which are therefore driven by different
groups of cams 18 whereby each of the groups defines one cam track.
Usually, the cams are fixed on a cam holder. Circular knitting
machines usually have a cam holder which is fixed on the machine
frame. Flat knitting machines are often provided with a carriage
which performs a relative movement with regard to the needle bed.
In most cases the "distance" 50 shall be a linear distance in
flat-knitting machines and a distance which comprises circular
components in circular knitting machines. There are additional
benefits if this measure is used with regard to needles which are
provided with butts 17 which have a width in the second direction x
which is equal or nearly equal to the combined joint width of
spacer 10 and system component 11, 12.
[0073] FIG. 11 once again shows a plain view of a third needle bed
14 in which pairs of system components 11, 12 are moved in one
groove 16. The said grooves 16 are once again delimited by
immovable walls 15. It is necessary to emphasize that the present
invention has also its benefits with regard to needle beds which
house 3, 4, 5, 6 or even more system components. The first system
components 11 and the second system components 12 have their butts
17 in different longitudinal y positions. Hence the first and
second system components 11, 12 are moved along different cam
tracks. Most interestingly, the spacers 10 of the embodiment shown
in FIG. 11 are bends 51 of the shanks of the respective system
components 11, 12. The bends 51 of the first system components 11
are in contact with the shanks 39 of the second system components
12 and vice versa. Therefore, no bend 51 or spacer 10 (which are
the same in this embodiment) touches another spacer's surface and
all spacers touch another's system components side surface.
[0074] FIG. 12 shows a top view of a fifth needle bed 14. Needle
beds of the kind shown in FIG. 12 are often used in circular
knitting machines. In the case of circular knitting machines the
needle bed 14 would also be called needle cylinder. FIG. 12 shows
an example of a loop-forming process which takes place in the
loop-forming zone 19. The needles 11, 12 and especially the hooks
20 and latches 24 take part in the loop forming process and
therefore get in contact with the yarn 23. The sinkers 25 also get
in contact with the yarn 23. The extension of the loops 33 in
x-direction is symbolized by the brackets 33. FIG. 12 also shows
some more details of the needles 11, 12 and the needle bed 14 which
are well known to the man skilled in-the-art: The latches 24 are
pivoted in the saw slot 26. During the loop forming process the
latches 24 swing around the pivot 27 so that the interior of the
hooks 20 is opened and closed for the yarn 23 by the latches 24.
During the loop forming process the needles essentially move in the
direction y of their shanks or of the grooves 16 of the needle bed
14. The sinkers 25 essentially move in the direction z of the
height of the shanks of the needles 11, 12. The needle bed 14 is
provided with slots 28 which look like teeth in the view provided
by FIG. 12. The slots 28 guide the sinkers' 25 movements. The
differences between the sinkers 25 and the spacers 10 can be
summarized as follows:
[0075] 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.
[0076] 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.
[0077] 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 FIG. 12 are provided with loop-forming means which have a width
which is identical with the width of their hooks since the hooks 20
are broader than the latches 24.
[0078] On the other hand FIG. 12 also provides a different
possibility to define the distance between adjacent loop-forming
means: The numeral 52 (see pointer 52) denotes the distance between
the centers of the hooks 20 of two adjacent system components. This
distance 52 is (of cause) equal to the distance of two adjacent
loops which are being formed by the respective hooks. The
man-skilled-in-the-art often calls this distance "pitch" (the pitch
denotes this distance in millimetres whereas the gauge is the
number of needles per inch). In most loop-forming methods and also
in most loop-forming devices this pitch is even (all system
components of one needle bed have the same distance with regard to
each other). Otherwise the knitted fabric produced by such a
machine would be perceived as uneven by the consumer. With regard
to the present invention one could also say that the spacer adjusts
or helps to adjust the pitch between adjacent needles or system
components.
[0079] FIG. 14 provides a plain view of the first groove 16 of the
needle bed 14 which is equipped with system components 11, 12. Each
of the system components 11, 12 is immovably connected with a
spacer 10 by means of a weld point 42. Therefore one could also
say, that the system component 11 and the spacer 10 with which it
is immovably connected form a system unit 54. The same applies with
regard to the other system component 12 and the respective spacer
10.
[0080] 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. FIG. 14 shows that the system component 11 is symmetrical
with regard to the symmetry line 53. This figure also shows that
the system unit 54 which moves together during the loop-forming
process is not symmetrical with regard to the line 53. The same
applies with regard to the system component 12 its spacer 10 and
the unit 54 which is formed by the two aforementioned elements.
FIG. 15 shows a slightly different excellent groove which is
equipped with two system components 11, 12 and one spacer 10 which
provides for the whole distance between the loop-forming means 20,
24 of the two adjacent system components 11, 12. The respective
spacer 10 is immovably connected by a plurality of weld points 53
(only one weld point is shown by FIG. 15) with the system component
11 so that the system components 11 and the spacer 10 once again
form a system unit 54 which is moved together during the loop
forming process. The system component 11 is symmetrical with regard
to symmetry line 53. Once again the unit 54 which is formed by the
system components 11 and the spacer 10 is not symmetrical with
regard to the aforementioned line 53. The system component 12 can
be a standard needle which is symmetrical to the other line 53
which cuts the respective system component in two halfs. The
embodiment shown in FIGS. 14 and 15 show that inventive embodiments
are most of the time provided with system units which are not
symmetrical with regard to symmetry line 53 which is parallel to
the side surfaces of the respective system component 11, 12 and
which crosses the centre of the hook 20. In this regard FIG. 16
shows an exceptional embodiment of a further groove 16 which is
delimited by the immovable walls 15 and the bottom of the groove
55. The system component 11 which is placed in the middle of the
groove and surrounded by two other system components 12 is
immovably connected with two spacers 10 whereby each of the spacers
10 is placed on one of the system component's 11 two different side
surfaces. Therefore the system component 11 and the two spacers 10
with which it is connected form another system unit 54. This system
unit 54 is symmetrical with regard to the symmetry line 53. The
same applies with regard to the other two system components 12
which can be stand-up needles. This is to say that the inventive
embodiments shown in FIG. 16 can be equipped with system units
(elements which form a unit which is moved together during the loop
forming process) which are symmetrical with regard to the symmetry
line 53. As mentioned above, the embodiments shown in FIGS. 14 and
15 are provided with at least one system unit which is not
symmetrical with regard to the symmetry line 53. This feature is
generally of benefit for inventive embodiments.
[0081] FIGS. 14, 15 and 16 elucidate another property of the
invention. The grooves 16 are broader (possess a bigger width in
the direction x) than state-of-the-art needle beds 14. Needle beds
which are appropriate for the present invention have a width which
is bigger 0,7 times the pitch 52, or even bigger than the pitch 52
are even bigger than 11/2 times the pitch 52. The grooves which are
provided with the aforementioned pitch can have a length which
equals 95, 90, 85, 80, 70 or 60% of the system components' length.
The respective grooves are easy to clean and the oil consumption of
the overall new device is smaller than in most state-of-the-art
devices. The broad grooves or channels are cheap and easy to grind
(especially if a small pitch is required).
TABLE-US-00001 List of numerals 10 Spacer/element 11 First
Needle/element/system component 12 Second Needle/element/system
component 14 Needle bed 15 Immovable wall which delimits two
grooves of a needle bed 16 Groove/channel for guiding elements 17
Butt of the elements 18 Cams 19 Loop-forming zone 20 hook 21
Distance between the needles 11 and 12 23 Yarn/Thread 24 Latch 25
Sinker 26 Saw slot 27 Pivot of the latch 28 Tooth of the needle bed
33 Bracket signifying the extension of a loop 35 Passage for the
butts 17 in the cam 18 37 Extrema of a passage 37 (in y-direction)
38 Additional part 39 Shank 40 Thick line which symbolizes the
limitation between spacer and shank 41 Segments of the longitudinal
extension of the grooves/Bracket signifying such a segment 42 weld
point 43 End section of the butt (in the first direction y) 44
Splint, dotted line signifying such a splint 45 Extension of the
butt in the first direction y 46 First width of the butt (end
section) 47 Second width of the butt (Middle section) 48 Limitation
of the passage 35 49 Middle section of the butt 50 Distance between
the extreme are of two cams of a different contract 51 bends 51 of
the shanks of the respective system components 52 Distance between
the centre of two adjacent hooks or pitch 53 symmetry line 54
System unit comprising a system component und the spacer(s) with
which it is connected 55 bottom of a groove x Direction of the
width of the shanks of the elements/grooves y Direction of the
length of the shanks of the elements/grooves z Direction of the
height of the shanks of the elements/grooves vk First
velocity/velocity of needle bed, relative velocity cam
holder/needle bed
* * * * *