CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This claims priority to U.S. Provisional Patent Application No. 63/403,503, filed September 2, 2022, the entire contents of which are incorporated herein by reference.

FIELD

[0002] This relates generally to knitting machines, and in particular to components for use with yarns, fibers, and other knitting fibers.

BACKGROUND

[0003] Knitting machines come in many different configurations and designs. For example, flat bed knitting machines typically include a flat elongate bed on which is retained a plurality of parallel, latchable needles equally spaced along the length of the bed. Each needle may be movable relative to the bed in a direction lengthwise of the needles and transverse of the bed length. Carriers supply the transmission of yam to the needles.

[0004] Conventional carriers are designed for use with conventional yams, and may not be suitable for all types of yams or with all materials used as yams. Accordingly, there is a need for knitting machines which provide improved performance with a wide variety of yams.

SUMMARY

[0005] According to an aspect, there is provided a carrier device for supplying a fiber, the carrier device comprising: a body; and a plurality of rollers connected to said body, said plurality of rollers being separated by a space and adapted for receiving said fiber in said space. [0006] According to another aspect, there is provided a knitting machine comprising at least one carrier device as described herein.

[0007] According to yet another aspect, there is provided a method of modifying a yarn carrier, the method comprising: removing an exit port from a distal end of said carrier; securing a pair of rollers to said distal end of said carrier; and passing a fiber through a space between said pair of rollers.

[0008] Other features will become apparent from the drawings in conjunction with the following description.

BRIEF DESCRIPTION OF DRAWINGS

[0009] In the figures which illustrate example embodiments,

[0010] FIG. 1 A is an illustration of the action of a assembly and carrier device during operation of a flat bed knitting machine;

[0011 ] FIG. 1 B is an illustration of a condition of a yam during operation of a flat bed knitting machine;

[0012] FIG. 2 is an illustration of an interior portion of an example yarn carrier in accordance with some embodiments;

[0013] FIG. 3 is an illustration of an interior portion of an example carrier in accordance with some embodiments,

[0014] FIG. 4 is an enlarged view of the interior portion of the example carrier of FIG. 3;

[0015] FIG. 5 is an isometric view of an example yarn carrier device in accordance with some embodiments;

[0016] FIG. 6A is an illustration of a bottom view of an example yam carrier device in accordance with some embodiments; [0017] FIG. 6B is an illustration of a front view of the example carrier device of

FIG. 6A; and

[0018] FIGs. 7A and 7B are illustrations of an operating relationship of a knitting machine incorporating a conventional carrier and an example yam carrier device in accordance with some embodiments.

DETAILED DESCRIPTION

[0019] Various aspects of preferred embodiments of the invention are described herein with reference to the drawings.

[0020] FIG. 1 A is an illustration of the action of an assembly and yam carrier during operation of a flat bed knitting machine. As depicted, flat bed knitting machine 100 includes a plurality of assemblies 102a, 102b, 102c. Each assembly supplies a different yam 150a, 150b, 150c. Assembly 102 provides a length of yam 150 which is fed through yam carriers 160a, 160b, 160c to the bed of needles (not pictured) along flat bed 170. It should be appreciated that although this disclosure refers to yams, principles in this disclosure apply more broadly to any type of conductive yam, fiber, and/or wires, and blends thereof (e.g. conductive and non-conductive fibers).

[0021] As depicted in FIG. 1A, assembly 102a and yam carrier 160a follow a path of motion in which yam 150a is stretched in a first direction 180 past the bed of needles, then raised vertically 182, and then translated in a second direction 184 substantially opposite to the first direction 180. During operation of a flat bed knitting machine, yam 150a is subjected to a number of tensile forces at a number of different angles. For example, as shown in FIG. 1A, during movement in directions 180, 182, 184, yam 150a is stretched horizontally while being fed vertically through carrier 160a, resulting in a substantially 90 degree angle at the exit port 190 of yam carrier 160a (which is circled in FIG. 1 B).

[0022] Many different types of fibers, fabrics and yams may be able to withstand the forces which assembly 102a and yam carrier 160a subject yam 150a to during operation of a flatbed knitting machine. This is because traditional yams are characterized by high flexural rigidity, flexibility, low friction, and generally being able to withstand substantial amounts of elongation (e.g. stretching). Moreover, new materials being developed for textile applications are tailored to using increasingly thin fabrics (e.g. higher gauge), and production speed and efficiency are emphasized above all other considerations.

[0023] However, to produce smart textile articles such as E-textiles and smart fabrics, conductive materials (e.g. conductive fibers, such as conductive yams) are required. Yam and fiber manufacturing technology has reached the point of producing conductive yams having high conductivity, but it remains a challenge to produce conductive yams having both high conductivity characteristics while maintaining normal yam features (e.g. high flexural rigidity, low friction, and being able to withstand a substantial amount of elongation or stretching).

[0024] The vast majority of conductive yams currently available do not have enough flexural rigidity or elongation to consistently withstand the tension, friction and angles that are applied at various steps during the knitting process, and in particular the 90 degree bends at the yam carrier 160a (sometimes referred to herein as “carrier”). This may result in breakage and/or failures during the knitting process. For example, some conductive fibers may include many filaments and fibers which are twisted together or are wrapped around a passive core, and high friction operations such as large angle bending may result in fraying and/or breakage, which may result in subsequent short circuits within a conductive fabric or between adjacent conductive sections, which is undesirable. Nevertheless, for many applications, embedding wires into the fabric or garment is the only practical option due to design constraints (e.g. a lack of insulation).

[0025] In essence, the materials typically used for modem knitting applications (which are high conductivity but lower flexibility, higher friction, and less able to withstand stretching) are not compatible with components on conventional knitting machines. Accordingly, it would be beneficial to modify knitting machine components to reduce the amount of tension and friction experienced by conductive yams, fibers and/or wires during knitting to accommodate modern e-textile and smart textile applications. In some embodiments, a modified carrier device 500 may facilitate the use of rigid conductive materials and reduce the stresses experienced by conductive yams, fibers and/or wires during the knitting process.

[0026] Returning now to FIGs. 1 A and 1 B, the assembly/carrier on conventional knitting machines releases the yam at a substantially 90 degree angle. A substantial amount of tension and friction is applied to a conductive yam at the tip of the yam carrier. Moreover, during motion direction 184, due to conductive yams being less elastic than traditional yams, conductive yams might not reliably run back and adjust when knitting changes directions. As such, after consuming the required amount of conductive yam, the extra pulled material might not run back into the hole on the yam carrier tip and then upward on the shaft of the carrier, due to lack of elasticity of conductive fibres. When this happens, this may result in a loop being unintentionally created at the carrier tip, which may result in dropped stitches, and/or a loose yam remaining in the knitting zone, resulting in problems operating other active knitting components and possible entanglements with other yams that are in use.

[0027] FIG. 2 is an illustration of an interior portion of an example carrier device 200 in accordance with some embodiments. As depicted, carrier device 200 includes specialized tubes 210 and eyelets 220. In some embodiments, tubes 210 and eyelets 220 may facilitate routing and directing of yarn/wire 150 to the distal end or exit port 190 of the carrier device 200.

[0028] FIG. 3 is an illustration of an interior portion of an example yam carrier device 300 in accordance with some embodiments. As depicted, carrier device 300 includes a plurality of rollers 310a, 310b in place of exit port 190. In some embodiments, a fiber 150 may be fed through a space between rollers 310a, 310b throughout operation of a knitting machine. In some embodiments, rollers 310 may avoid or reduce friction experienced by yarn/wire 150. For example, when the knitting direction changes during operation, yarn/wire 150 may run more easily back into eyelet 220 and tube 210, as rollers 310 may rotate as yarn/wire 150 moves (rather than rubbing against exit port 190, which causes friction and may leads to degradation of yarn/wire 150). In some embodiments, use of carrier device 300 may reduce the frequency of occurrence of loops and dropped stitches at the exit port or prevent loops and dropped stitches at the carrier tip entirely. FIG. 4 is an enlarged view of the interior portion of the example carrier device 300 of FIG. 3.

[0029] FIG. 5 is an isometric view of an example carrier device 500 in accordance with some embodiments. As depicted, the lower portion of a conventional carrier device 160 including exit port 190 has been removed, leaving instead first and second protrusions 510, 520. It should be appreciated that in other embodiments, more or less than two protrusions are contemplated. In some embodiments, carrier device 500 may be manufactured with protrusions 510, 520, without the inclusion of exit port 190 and subsequent removal of exit port 190. It will be appreciated that some embodiments may include retrofitting a conventional carrier device which already comprises exit port 190, whereas other embodiments may include purpose-built carrier devices which do not include exit port 190. The carrier device 500 described in FIG. 5 may allow for retrofitting or modifying a yam carrier on an existing knitting machine to better accommodate high conductivity conductive fibers and yams which are less flexible and rigid than conventional yams.

[0030] As depicted, carrier device 500 includes a housing 530 which receives protrusions 510, 520 and secures rollers 310a, 310b in place. As depicted, housing 530 includes two interlocking portions 530a, 530b. Likewise, portion 530a may include recesses 515a, 525a which are complementary in shape with protrusions 510, 520, respectively. Likewise, portion 530b may include recesses 515b, 525b which are complementary in shape with protrusions 510, 520, respectively.

[0031] In some embodiments, first and second portions of housing 530 may include a connection means for flexible interlocking portions 530a, 530b. In some embodiments, the connection may be via frictional engagement. In some embodiments, a fastener may be placed through one or more of ports 540a, 540, and 545a, 545b to connect portions 530a, 530b to create housing 530. In some embodiments, a fastener 610a, 610b may further act as an axle about which roller 310 may rotate. In some embodiments, the fastener 610 may be a screw configured to interact with threading in ports 540a, 540b and/or 545a, 545b, respectively.

[0032] FIG. 6A is an illustration of a bottom view of an example carrier device 500 in accordance with some embodiments. As depicted, fasteners 610a, 610b connect first and second portions 530a, 530b of housing 530 and act as axles for rollers 310a, 310b. As depicted, fasteners 610a, 610b are screws. It will be appreciated that other fasteners (e.g. nails, nuts, bolts, studs, rivets, and the like). FIG. 6B is an illustration of a front view of the example carrier device of FIG. 6A.

[0033] FIGs. 7A and 7B are illustrations of an operating relationship of a knitting machine incorporating conventional yam carriers 160 and an example carrier device 700 in accordance with some embodiments. As depicted, carrier device 700 may be implemented using metal rather than plastic, which may allow for a more compact construction. For example, carrier device 700 may function with a 7.2 gauge knitting machine. In some embodiments, use of plastic materials for carrier device 500 may result in occupying the space of between 5 and 6 yarn carriers. This may be acceptable for some applications and might not acceptable for other applications. It will be appreciated that dimensions described herein are merely exemplary and that carrier devices 500, 700 may be larger or smaller scales than the specific embodiments described herein, and that other gauges are also contemplated.

[0034] Nevertheless, irrespective of the material used for carrier device 300,500,700, in some embodiments, such a carrier device may be used alongside conventional yam carriers 160 in an existing knitting machine with minimal or no additional modifications made to the knitting machine. Various yams, including but not limited to elastic yams for compression applications, carbon fibers, conductive yams, and the like, may experience less friction during knitting, which may allow for better performance of the materials and for more advanced applications.

[0035] In some embodiments, the use of rollers 310a, 310b may result in the angle experienced by the fiber 150 being knit being substantially less than 90 degrees (as depicted, for example, in FIG. 4). Rather than a sharp angle at exit port 190, the fiber 150 being knit may instead bend along the curved surface of rollers 310, which greatly reduces the likelihood of degradation and breakage. Moreover, carrier device 300, 500, 700 may allow relatively stiff fibers being knit to roll back during certain motions of carrier 102 without stiff fibers “floating” on the knitting area.

[0036] In some embodiments, carrier device 300, 500, 700 may function with a 7.2 gauge knitting machine. However, it will be appreciated that many ranges of gauge and knitting materials may be used in connection with carrier device 300, 500, 700 while remaining within the scope of the principles and embodiments disclosed herein. In some embodiments, carrier device 300, 500, 700 is suitable for use with any flat bed knitting machine which has individual yam carriers.

[0037] Of course, the above-described embodiments are intended to be illustrative only and in no way limiting. The described embodiments are susceptible to many modifications of form, arrangement of parts, details, and order of operation. The invention is intended to encompass all such modification within its scope, as defined by the claims.