TECHNICAL FIELD
[0001] The present invention relates to a method of knitting tubular knitted fabric through
a double system knitting with a flat knitting machine, and a tubular knitted fabric
knitted with the method.
BACKGROUND ART
[0002] A flat knitting machine generally includes at least a pair of front and back needle
beds, a carriage that reciprocates on the needle bed, and a plurality of rails lined
in parallel in a direction orthogonal to the longitudinal direction of the needle
beds at above the needle beds. The carriage includes a plurality of cam systems for
driving the knitting needles lined on the needle beds to perform the knitting operation.
Each rail has a yarn feeder attached so as to be slidable in a direction parallel
to the longitudinal direction of the needle beds.
[0003] One of knitting techniques using the flat knitting machine includes double system
knitting (e.g., Patent Document 1). In the double system knitting, the plurality of
yarn feeders are entrained by the carriage, and the yarn is fed from each yarn feeder
with respect to each knitting needle driven by each preceding and following cam system
of the carriage. The knitting two courses thus can be carried out with the movement
of the carriage in one direction.
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
[0004] Patent Document 1: Japanese Laid-Open Patent Publication No.
10-266047
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0005] However, when knitting the knitted fabric to a tubular shape with the conventional
double system knitting, problematically, the knitting yarn fed from the preceding
yarn feeder and the knitting yarn fed from the following yarn feeder cross at one
end in a knitting width direction, which is a reverse position of the yarn feeder,
whereby a hole forms in the knitted fabric due to such crossing.
[0006] For example, a case of knitting a tubular knitted fabric in a counterclockwise direction
(direction of thin arrow in the drawing) is illustrated in Fig. 5 (A), with a yarn
feeder 5 on the near side when seen from the front side of the flat knitting machine
as the following yarn feeder and a yarn feeder 6 on the far side than the yarn feeder
5 as the preceding yarn feeder. In Fig. 5 (A), the lower side of a paper face is the
front needle bed, the front knitted fabric portion FF of the tubular knitted fabric
being knitted at the front needle bed, and the upper side of the paper face is the
back needle bed, the back knitted fabric portion BF of the tubular knitted fabric
being knitted at the back needle bed. Fig. 5(B) is a loop diagram of the portion indicated
with a chain double dashed line in Fig. 5 (A) when seen from a direction of an outlined
arrow.
[0007] When carrying out the knitting shown in Fig. 5(A), the knitting yarn from the yarn
feeder 5, which is knitted afterwards, crosses the knitting yarn fed from the yarn
feeder 6, which is of the knitting course formed before, at the left end (portion
surrounded with the chain double dashed line) in the knitting width direction when
transitioning from the knitting at the back needle bed to the knitting at the front
needle bed. If the knitting at the front needle bed is further started from such a
state, the crossing state of the knitting yarn from the yarn feeder 5 and the knitting
yarn from the yarn feeder 6 reflects on the knitted fabric. As shown in Fig. 5(B),
a sinker loop (portion connecting two adjacent stitches of the same course) of the
knitting course knitted with the knitting yarn from the yarn feeder 6 is pulled up
by a sinker loop of the knitting course knitted with the knitting yarn from the yarn
feeder 5 thereby forming a large hole g in the knitted fabric at a boundary portion
X of the front knitted fabric portion FF and the back knitted fabric portion BF due
to such crossing. As apparent from Fig. 6, which shows a photograph of the actual
knitted fabric, the hole g has a size that can be visually recognized, and hence may
affect the outer appearance of the knitted fabric. The photograph of Fig. 6 and the
photographs of Fig. 2 and Fig. 4, to be described later, are taken with the knitted
fabric pulled in the knitting width direction.
[0008] The problem of crossing described above occurs at the right end in the knitting width
direction if the yarn feeder 5 is the preceding yarn feeder and the yarn feeder 6
is the following yarn feeder. In Fig. 5, an example in which two knitting yarns are
fed from one yarn feeder has been shown, but similar problem may obviously occur even
if one knitting yarn is fed from one yarn feeder.
[0009] The present invention has been made in view of the above, and it is an object of
the present invention to provide a knitting method of tubular knitted fabric in which
a large hole does not form at the boundary portion of the front knitted fabric portion
and the back knitted fabric portion even when knitting the knitted fabric to a tubular
shape through the double system knitting, and a tubular knitted fabric knitted with
the knitting method.
MEANS FOR SOLVING THE PROBLEMS
[0010] The knitting method of tubular knitted fabric of the present invention is a knitting
method of a tubular knitted fabric using a flat knitting machine, which has at least
a pair of front and back needle beds and is configured to drive knitting needles of
the needle beds to perform a knitting operation by a plurality of cam systems arranged
in a carriage that reciprocates on the needle beds and also has a plurality of yarn
feeders attached to reciprocate in a direction parallel to the longitudinal direction
of the needle beds with respect to each of a plurality of rails laid in parallel in
a direction orthogonal to a longitudinal direction of the needle beds at above the
needle bed, in which two courses are knitted with the preceding cam system and the
following cam system by the movement of the carriage in one direction. Assuming the
yarn feeder on the front side of the yarn feeders arranged in the flat knitting machine
is a near side yarn feeder, the yarn feeder positioned on a far side than the near
side yarn feeder is a far side yarn feeder, and the yarn feeder positioned between
the near side yarn feeder and the far side yarn feeder is a middle side yarn feeder,
the knitting method of tubular knitted fabric of the present invention feeds yarns
from the near side yarn feeder and the far side yarn feeder with respect to the knitting
needle driven by either one of the cam systems, the preceding cam system or the following
cam system, and feeds yarns from the middle side yarn feeder with respect to the knitting
needle driven by the other one of the cam systems to carry out knitting to a tubular
shape.
[0011] The knitting method of tubular knitted fabric of the present invention preferably
feeds the yarns from the near side yarn feeder and the far side yarn feeder with respect
to the knitting needles driven by the preceding cam system. In other words, the yarn
is preferably fed from the middle side yarn feeder with respect to the knitting needle
driven by the following cam system.
[0012] The tubular knitted fabric of the present invention is a tubular knitted fabric including
front and back knitted fabric portions knitted by using a flat knitting machine, which
has at least a pair of front and back needle beds and is configured to drive knitting
needles of the needle beds to perform a knitting operation by a plurality of cam systems
arranged in a carriage that reciprocates on the needle beds and also has a plurality
of yarn feeders attached to reciprocate in a direction parallel to the longitudinal
direction of the needle beds with respect to each of a plurality of rails laid in
parallel in a direction orthogonal to a longitudinal direction of the needle beds
at above the needle beds, in which the front and back knitted fabric portions are
knitted by carrying out knitting two courses with the preceding cam system and the
following cam system by the movement of the carriage in one direction. The tubular
knitted fabric is formed by alternately repeating a first knitting course made up
of a plurality of knitting yarns and a second knitting course made up of one or more
knitting yarns. In the tubular knitted fabric of the present invention, some of the
knitting yarns of the plurality of knitting yarns configuring a sinker loop of the
knitting yarns of the first knitting course cross a sinker loop of the second knitting
course adjacent to the first knitting course, and the remaining knitting yarns do
not cross the sinker loop of the second knitting course at a boundary portion of the
front knitted fabric portion and the back knitted fabric portion.
EFFECTS OF THE INVENTION
[0013] According to the knitting method of tubular knitted fabric of the present invention,
the knitting yarn from the middle side yarn feeder and the knitting yarn from the
far side yarn feeder do not cross if the knitting yarn from the near side yarn feeder
and the knitting yarn from the middle side yarn feeder cross when the knitting of
the front knitted fabric portion of the tubular knitted fabric and the knitting of
the back knitted fabric portion of the tubular knitted fabric are switched. The knitting
yarn from the middle side yarn feeder and the knitting yarn from the near side yarn
feeder do not cross if the knitting yarn from the far side yarn feeder and the knitting
yarn from the middle side yarn feeder cross when the knitting of the front and back
knitted fabric portions is switched. That is, even if the tubular knitted fabric is
knitted through the double system knitting, a knitting yarn to which the sinker loop
does not cross always exists at both boundary portions (boundary portions on the left
and the right in the knitting width direction of the knitted fabric) of the front
knitted fabric portion and the back knitted fabric portion. As a result, the non-crossing
knitting yarn bridges across the front and back knitted fabric portions as a sinker
loop of a normal shape at the position of the hole formed by crossing, and hence the
formed hole does not outstand and the appearance of the boundary portion becomes satisfactory.
Furthermore, the knitting yarn to which the sinker loop crosses and the knitting yarn
to which the sinker loop does not cross exist at both boundary portions of the knitted
fabric, and hence both boundary portions can have almost the same appearance, and
a knitted fabric with balanced appearance and a beautiful finish can be obtained.
Furthermore, the productivity of the knitted fabric can be enhanced since knitting
is carried out through the double system knitting.
[0014] The first knitting course to which knitting yarns are fed from the near side yarn
feeder and the far side yarn feeder is formed before the second knitting course to
which knitting yarns are fed from the middle side yarn feeder by feeding the yarns
from the near side yarn feeder and the far side yarn feeder with respect to the knitting
needles driven by the preceding cam system. In this case, the knitting yarns from
the middle side yarn feeder cross one of the knitting yarns, the knitting yarn from
the near side yarn feeder or the knitting yarn from the far side yarn feeder, that
are already formed, and pull up the one of the knitting yarns towards the second knitting
course at the boundary portion of the front and back knitted fabric portions. The
shape of the sinker loop at the boundary portion X formed of the knitting yarns from
the middle side yarn feeder does not greatly deform with respect to the shape of the
sinker loop at other than the boundary portion X in the same knitting course (see
sinker loop originating from the yarn feeder 5 of Fig. 1 (B), to be hereinafter described).
The knitting yarns from the middle side yarn feeder do not cross the other one of
the knitting yarns, and such other knitting yarn maintains the state when it has been
formed. That is, the sinker loops are the same in height in the knitted fabric and
the shapes of such sinker loops are uniform in all knitting courses of the knitted
fabric, and hence the appearance of the knitted fabric is satisfactory (see Fig. 1
(B)). In this case as well, the left and right boundary portions in the knitted fabric
have almost the same appearance, and a knitted fabric with balanced appearance and
a beautiful finish can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015]
Fig. 1 (A) is an explanatory view showing a state of yarn feeders when knitting through
a knitting method of a tubular knitted fabric described in a first embodiment. (B)
is a loop diagram showing a boundary portion of the front and back knitted fabric
portions at the side surrounded with a dotted line in (A) when seen from the direction
of an outlined arrow.
Fig. 2 is a photograph of the vicinity of the boundary portion in the tubular knitted
fabric described in the first embodiment.
Fig. 3 (A) is an explanatory view showing a state of the yarn feeders when knitting
through a knitting method of a tubular knitted fabric described in a second embodiment.
(B) is a loop diagram showing a boundary portion of the front and back knitted fabric
portions at the side surrounded with a dotted line in (A) when seen from the direction
of an outlined arrow.
Fig. 4 is a photograph of the vicinity of the boundary portion in the tubular knitted
fabric described in the second embodiment.
Fig. 5(A) is an explanatory view showing a state of the yarn feeders when knitting
through a knitting method of a tubular knitted fabric of the background art. (B) is
a loop diagram showing a boundary portion of the front and back knitted fabric portions
at the side surrounded with a dotted line in (A) when seen from the direction of an
outlined arrow.
Fig. 6 is a photograph of the vicinity of the boundary portion in the tubular knitted
fabric of the background art.
MODE FOR CARRYING OUT THE INVENTION
[0016] Preferred embodiments (first and second embodiments) of the present invention will
be described below in detail with reference to the drawings. In both the first and
second embodiments, a tubular knitted fabric including a front knitted fabric portion
knitted at a front needle bed and a back knitted fabric portion knitted at a back
needle bed is knitted through the double system knitting of carrying out the knitting
two courses at once by one forward movement or backward movement of a carriage arranged
in the flat knitting machine. The tubular knitted fabric of the present invention
includes, of course, a tubular article (e.g., sweater) in which the front and back
knitted fabric portions are completely continued, but also an article (e.g., cardigan)
in which one part of the tube is not continued.
[0017] First, the flat knitting machine used in the embodiment will be described. The flat
knitting machine is a flat knitting machine having a pair of front and back needle
beds extending in a transverse direction and disposed opposite to each other in a
cross direction. Such a flat knitting machine includes a two-bed flat knitting machine
including a front needle bed and a back needle bed, and a four-bed flat knitting machine
including another pair of needle beds disposed opposite to each other at above the
front and back needle beds.
[0018] The flat knitting machine includes a plurality of rails laid in parallel in a direction
orthogonal to the longitudinal direction of the needle beds at above the needle beds
regardless of how many needle beds are arranged. Each rail has a yarn feeder attached
so as to be slidable on the rail, which yarn feeder can reciprocate in a direction
parallel to the longitudinal direction of the needle bed. In Fig. 1 and Fig. 3 used
in the description of the first and second embodiments described afterward, only three
yarn feeders, a yarn feeder 4, a yarn feeder 5, and a yarn feeder 6 are illustrated.
The positional relationship of such yarn feeders 4 to 6 is a positional relationship
in which the yarn feeder 4 (near side yarn feeder) is arranged on the nearest side
when seen from the front side of the flat knitting machine, the yarn feeder 6 (far
side yarn feeder) is arranged on the farthest side, and the yarn feeder 5 (middle
side yarn feeder) is arranged between the yarn feeder 4 and the yarn feeder 6.
[0019] Furthermore, the flat knittingmachine includes a carriage mounted with a plurality
of cam systems for driving the knitting needles of the needle beds. In the knitting
method of tubular knitted fabric of the present invention, the double system knitting
is carried out by using two of the plurality of cam systems to form stitches. If three
or more cam systems are arranged, two may be used for forming the stitches, and the
remaining one may be used for transfer, and the like.
<First Embodiment>
[0020] The tubular knitted fabric including a back knitted fabric portion BF and a front
knitted fabric portion FF as shown in Fig. 1 is knitted using the flat knitting machine
described above. Fig. 1 (A) is a view showing a positional relationship of the yarn
feeders 4, 5, 6 at the time of knitting. A thin arrow in the figure shows the movement
direction of the yarn feeders 4, 5, 6 (same as the movement direction of the carriage),
where the front knitted fabric portion FF is knitted at the front needle bed on the
lower side of the paper face and the back knitted fabric portion BF is knitted at
the back needle bed on the upper side of the paper face with the movement of the yarn
feeders 4, 5, 6. Fig. 1 (B) is a loop diagram of the portion shown with a chain double
dashed line in Fig. 1 (A) when seen from the direction of an outlined arrow, where
a boundary portion X of the front knitted fabric portion FF and the back knitted fabric
portion BF is shown with a chain line. Fig. 3 used in the description of the second
embodiment, described afterwards, is viewed in the same manner.
[0021] When continuously knitting the front knitted fabric portion FF and the back knitted
fabric portion BF, one knitting yarn is fed from each of the yarn feeders 4 and 6
with respect to the knitting needles driven by the preceding cam system, and two knitting
yarns are fed from the yarn feeder 5 with respect to the knitting needles driven by
the following cam system. In this case, the yarn feeders 4 and 6 are traveled so as
to be ahead of the yarn feeder 5. The order of the yarn feeder 4 and the yarn feeder
6 in the carriage is not particularly limited, and may be exactly simultaneous as
long as the distal ends of the yarn feeders 4, 6 do not interfere with each other.
[0022] The thickness of the knitted fabric becomes uniform if the number of knitting yarns
is the same for the knitting with the preceding cam system and for the knitting with
the following cam system, and a satisfactory appearance of the knitted fabric is realized
if the knitting yarns to be knitted with both cam systems are the same color. Therefore,
in the present embodiment, one knitting yarn of the same color is fed from each of
the yarn feeders 4 and 6, and two knitting yarns of the same color are fed from the
yarn feeder 5. Instead of feeding two knitting yarns from the yarn feeder 5, one knitting
yarn may be fed from the yarn feeder 5 and a yarn feeder 5' (not illustrated) separate
from the yarn feeder 5, respectively, as following yarn feeders. In this case, the
yarn feeder 5' that is on the far side than the yarn feeder 4 and on the near side
than the yarn feeder 6 is used.
[0023] When the double system knitting is carried out with the yarn feeders 4 to 6 having
the above positional relationship, a first knitting course made up of two knitting
yarns fed from the yarn feeders 4 and 6 forms before a second knitting course made
up of two knitting yarns fed from the yarn feeder 5. In this case, the knitting yarns
of the yarn feeder 5 cross the knitting yarn of the yarn feeder 6 when the knitting
of the back knitted fabric portion BF is finished at the left end in the knitting
width direction (portion surrounded with a chain double dashed line in Fig. 1 (A))
at where the knitting of the back knitted fabric portion BF transitions to the knitting
of the front knitted fabric portion FF. When the knitting of the front knitted fabric
portion FF then starts, the knitting yarns of the yarn feeder 5 pull up the knitting
yarn of the yarn feeder 6. The knitting yarn of the yarn feeder 4 does not cross the
knitting yarns of the yarn feeder 5, and hence is not pulled up by the knitting yarns
of the yarn feeder 5 when transitioning from the knitting of the back knitted fabric
portion BF to the knitting of the front knitted fabric portion FF.
[0024] The state of the stitches at the boundary portion X of the front knitted fabric portion
FF and the back knitted fabric portion BF at the left end in the knitting width direction
of the tubular knitted fabric knitted in the above manner is as shown in Fig. 1(B).
As shown in the figure, a sinker loop originating from the yarn feeder 6 of the sinker
loops of the first knitting course is hooked to a sinker loop (originating from the
yarn feeder 5) of the second knitting course formed after the first knitting course,
and is pulled up towards the second knitting course at the boundary portion X of the
knitted fabric. In this case, the shape of the sinker loop originating from the yarn
feeder 5 has a shape substantially the same as the shape of a normal sinker loop (sinker
loop at other than the boundary portion X). That is, in the second knitting course,
the sinker loop at the boundary portion X has substantially the same shape and has
substantially the same height as the sinker loop at other than the boundary portion
X. At the boundary portion X, the sinker loop originating from the yarn feeder 4 does
not cross the sinker loop of the second knitting course and thus is not pulled up
towards the second knitting course at all, and maintains the state when it has been
formed (state hooked to a pair of stitches sandwiching the boundary portion X of the
second knitting course formed one before the first knitting course).
[0025] As described above, the sinker loops are the same in height in the knitted fabric
and the shapes of such sinker loops are uniform in all knitting courses of the knitted
fabric, and hence the appearance of the knitted fabric is satisfactory. It is apparent
that a hole is not formed from the photograph (Fig. 2) showing a state at the boundary
portion X of the actual knitted fabric.
[0026] At the right end in the knitting width direction, the knitting yarn of the yarn feeder
4 crosses the knitting yarns of the yarn feeder 5 and is pulled up by such knitting
yarns, but the knitting yarn of the yarn feeder 6 does not cross the knitting yarns
of the yarn feeder 5 and is not pulled up by such knitting yarns. Thus, a hole does
not form even at the boundary portion of the front and back knitted fabric portions
at the right end in the knitting width direction.
[0027] The boundary portion X at the left end in the knitting width direction and the boundary
portion at the right end in the knitting width direction are different in that the
knitting yarn forming the first knitting course that crosses the knitting yarns (originating
from the yarn feeder 5) forming the second knitting course is either from the yarn
feeder 6 or the yarn feeder 4, but are the same in that one of the two knitting yarns
forming the first knitting course is pulled up but the remaining knitting yarn is
not pulled up. Thus, both boundary portions in the knitted fabric have almost the
same appearance, and a knitted fabric with balanced appearance and a beautiful finish
is obtained.
<Second Embodiment>
[0028] In the first embodiment, the knitting yarns from the middle side yarn feeder are
fed for the knitting with the following cam system, but may be fed for the knitting
with the preceding cam system. A case of feeding the yarns from the middle side yarn
feeder for the knitting with the preceding cam system will be described below with
reference to Fig. 3 and Fig. 4.
[0029] As shown in Fig. 3 (A), the yarn feeders 4 to 6 are arranged in the order from the
front surface to the rear of the flat knitting machine in the double system knitting
of the present embodiment. The carriage is moved towards the left of a paper face
to knit the back knitted fabric portion BF, and then the carriage is moved towards
the right of the paper face to knit the front knitted fabric portion FF.
[0030] When the above knitting is carried out, the second knitting course made up of two
knitting yarns fed from the yarn feeder 5 forms before the first knitting course made
up of two knitting yarns fed from the yarn feeders 4 and 6. In this case, the knitting
yarn of the yarn feeder 4 crosses the knitting yarns of the yarn feeder 5 when the
knitting of the back knitted fabric portion BF is finished at the left end in the
knitting width direction (portion surrounded with a chain double dashed line in Fig.
3 (A)) at where the knitting of the back knitted fabric portion BF transitions to
the knitting of the front knitted fabric portion FF. When the knitting of the front
knitted fabric portion FF then starts, the knitting yarn of the yarn feeder 4 pulls
up the two knitting yarns of the yarn feeder 5. In other words, the knitting yarn
of the yarn feeder 4 is pulled down by the two knitting yarns of the yarn feeder 5.
The knitting yarn of the yarn feeder 6 does not cross the knitting yarns of the yarn
feeder 5, and hence is not be pulled down by the knitting yarns of the yarn feeder
5.
[0031] Fig. 3(B) shows a state of the stitches at the boundary portion X at the left end
of the knitted tubular knitted fabric. As shown in the figure, a sinker loop originating
from the yarn feeder 4 of the sinker loops of the first knitting course is hooked
to a sinker loop of the second knitting course formed before the first knitting course,
and is pulled down towards the second knitting course at the boundary portion X. At
the boundary portion X, the sinker loop originating from the yarn feeder 6 does not
cross the sinker loop of the second knitting course, and thus is not pulled down towards
the second knitting course at all, and becomes the sinker loop of the same shape as
the sinker loop in the case where the normal knitting is carried out, that is, the
same shape as the sinker loop at a position other than the boundary portion X in the
same knitting course. More specifically describing, the sinker loop originating from
the yarn feeder 6 is in a state hooked to a pair of stitches sandwiching the boundary
portion X of the second knitting course formed one before the first knitting course.
[0032] The knitting method of the tubular knitted fabric of the present embodiment is similar
to the conventional double system knitting in that the sinker loop of the knitting
course (second knitting course) formed before is pulled up and deformed by the sinker
loop of the knitting course (first knitting course) formed after, thereby forming
a hole in the knitted fabric at the boundary portion X of the front knitted fabric
portion FF and the back knitted fabric portion BF. However, the hole that forms at
the boundary portion X is very small due to the non-crossing sinker loop originating
from the knitting yarn of the yarn feeder 6. In fact, it can be seen from the photograph
(Fig. 4), which shows a state at the boundary portion of the knitted fabric knitted
through the knitting method of the tubular knitted fabric of the present embodiment,
that a hole big enough to be considered a hole is not formed compared to the knitted
fabric (Fig. 6) knitted through the conventional knitting method.
[0033] At the right end in the knitting width direction, the knitting yarn from the yarn
feeder 6 crosses the two knitting yarns from the yarn feeder 5 and pulls up such knitting
yarns, but the knitting yarn of the yarn feeder 4 does not cross the two knitting
yarns from the yarn feeder 5 and does not pull up such knitting yarns. That is, the
right end in the knitting width direction also has an appearance similar to the left
end in the knitting width direction described above, and thus the appearance significantly
improves compared to the knitted fabric knitted through the conventional knitting
method.
INDUSTRIAL APPLICABILITY
[0034] The knitting method of tubular knitted fabric of the present invention can be suitably
used in the double system knitting capable of carrying out knitting two courses with
the movement of the carriage in one direction.
DESCRIPTION OF SYMBOLS
[0035]
- 4, 5, 6
- yarn feeder
- FF
- front knitted fabric portion
- BF
- back knitted fabric portion
- X
- boundary portion of front and back knitted fabric portions
- g
- hole