US3522715A - Circular warp knitting machine - Google Patents

Description

Aug. 4, 1970 R. E.4 MERRITT ETAI- cIRcULAR WAR?" KNITTING MACHINE l0 Sheets-Sheet l Filed Oct. 18, 1967 Robe-2T E. MesasznTT/Z ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL' CIRCULAR WARP'KNITTING MACHINE l0 Sheets-Sheet 2 Filed Oct. 18. 1967 TN N mno .MR r O v2 w W. E M A M. EJMI T5 Wd R.. ET if@ CnD Nm 5T w o mw; P VQ k. ,fr +90@ i? mju o :Il @O mo. Ow n v Nb v m` wg Aug- 4, 1970 R. E. MERRITT ETAL 3,522,715

CIRCULAR WARP KNITTING MACHINE Filed Oct. 18. 1967 10 Sheets-Sheet 5 ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR WARP KNITTING MACHINE 10 Sheets-Sheet L Fld Oct. 18. 1967' .L ,ya 1 W w Vw@ ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR WAR? KNITTING MACHINE Filed oct. 18'. 19s? 1o sheets-sheet s ATTGRNEYS Aug. 4, 1970 R. E. MERRl'r-r ET Al- 3,522,715

CIRCULAR WARP KNITTING MACHINE 10 Sheets-Sheet 6 Filed Oct. 18, 1967 l45 o y), d

ATTORNEYS Augy4, 1970 R. E. MERRITT ETAI- CIRCULAR WAR? "KNITTING MCHINE l0 Sheets-Sheet 7 Filed Oct. 18. 1967 INVENTORS: 22H-Tand l .-12 RQBERT E: ME

Cmns *T SMMONS www4/@MMM ATTORNEYS R. E. MERRITT ETAL CIRCULAR WARFKNITTING MACHINE Aug. 4, 1970 l0 Sheets-Sheet 8 Filed Oct. 18. 1967 INVENTORSI EQBEET E. Measzm and Owens .T SIMMONS BYMl/{jq/sm ATTORNEYS Aug. 4, 1970 R. E. MERRITT ET AL 3,522,715

CIRCULAR "ARP KNITTING MACHINE l0 Sheets-Sheet 9 Filed Oct. 18. 1967 TR my NM M d IEdSM TMI Q S E Il I: (if: l l i l Z BYM.

ATTORNEYS Aug. 4, 1970 R. E. MERRITT ETAI- 3,522,715

CIRCULAR WARPKNITTINC MACHINE 4Filed oct. 18. 19s? 1o sheets-sheet 1o INVENTORS RQBERT E'. MEEExTTand ATTORNEYS United States Patent ABSTRACT OF THE DISCLOSURE Sets of warp yarns are selectively guided to a circular series of latch needles as they are simultaneously raised and lowered to rapidly form an open lace type tubular fabric having periodically interconnected stitch chains. The rate of yarn feed and fabric taken up is varied to change the size of the stitches -being formed and to thereby fashion the tube `as it is knit. Pattern control means is provided for transversely cutting the seamless tubular fabric after a predetermined number of courses have been knit to form individual stocking `blanks and the like. Means is also provided for longitudinally slitting the fabric adjacent the lateral cut to form blanks suitable for use in the formation of full length tights and the like.

This invention relates generally to circular Warp knit fabrics, a circular warp knitting machine and a method of knitting such fabric and more particularly to such a machine and method wherein a wide variety of different types of open lace, 'Raschel type, Warp knit tubular fabrics of particularly high quality may lbe produced in a rapid and economical manner.

Warp knitting machines are generally flat-bed machines provided with a flat needle bed and a plurality of guide bars for directing individual yarns to different needles. It is also known to provide two needle beds on such machines of the Raschel type to thereby permit the knitting of tubular fabric on such machines.

Machines of this latter type are particularly useful in making open lace tubular stockings or so-called ishnet stockings characterized by periodically interconnected stitch chains. For example, such two bed -Raschel machines may be set up to knit thirty or more tubes simultaneously across the width of the bed at a speed of about 250 courses per minute. A disadvantage of these machines is that they represent a rather largeinvestment for a mill owner and that it is rather difficult to obtain uniform stitch size; particularly where the fabric from the front and back needle bars are connected together at opposite sides. These connector stitch chains at opposite sides include looser or longer stitches which form fault lines extending down opposed sides of the tubular fabric.

The basic concept of circularizing the needle bed of a warp type knitting machine has been known for many years and has been employed in highly simplified machines designed to knit incandescent gas mantles for gas lamps. However, the adaptation of this concept to a hosiery machine for knitting open lace-type fabric has not heretofore been known. However, we have found that such concept can Ibe adapted with certain modifications into a hosiery machine with the surprising result that open lace type stocking blanks free from fault lines can be knit thereon at rates of speed of up to 1800 or more courses per minute.

With the foregoing in mind, it ils an object of the present invention to provide an open lace type tubular fabric of particularly high quality which is knit on a circular warp knitting machine capable of producing a wide variety of different types of interconnected stitch chain patice terns and at a very rapid rate of speed, such as up to 1800 or more courses per minute.

It is a further object of the present invention to provider a positive take-up means for withdrawing the knit tube from the circular warp knitting machine at a predetermined rate and positive yarn feeding means for feeding. Athe yarns to the needles at a predetermined rate relative4 to the fabric take-up. Common drive means is provided for the take-up and the yarn feed and the speed of the common drive means determines the size of the stitch loop being knit. The machine includes a lvariable speed drive which controls the common drive means for the take-up and yarn feed so that the size of the stitch loop may be varied during the knitting of a single stocking blank to thereby provide fashioning of the blank.

In accordance with another feature of this invention, the circular warp knitting machine` may be provided with severing means supported to transversely cut the knit tube at selected intervals and form stocking blanks of the desired length. And further, automatic means may be incorporated on the machine to longitudinally cut or slit the fabric from a point adjacent the transverse cut line so that a leotard or tights-type garment blank may 'be formed on the machine. In forming garments therefrom the slit inner portions of adjacent pairs of stocking blanks maybe connected together, either directly or by means of an additional crotch piece.

Some of the objects of the invention having been stated, other objects will lappear as the description proceeds when taken in connection with the accompanying drawings, in which L FIG. 1 is a side elevation of the circular warp knitting machine of the present invention and showing only the forward portion of the yarn creel therefor;

IFIG. 2 is an enlarged side elevation of the opposite side of the central portion of the knitting machine shown in FIG. 1;

FIG. 3 is a vertical sectional View through the positive yarn feeding means and illustrating the manner in which the yarns are wrapped around the positive feed drive shaft as they are withdrawn from the yarn creel and moved toward the knitting needles;

FIG. 4 is a plan view of the knitting machine;

FIG. 5 is a front elevation of the central portion of the machine, looking inwardly from right to left in FIG. 2; FIG. 6 is an enlarged fragmentary vertical sectional view taken substantially along the line 6 6 in FIG. 5 and illustrating the fabric cutting land .slitting means;

FIG. 7 is a fragmentary isometric view of a portion of the knitting machine, looking inwardly at the needle cylinder from the left-hand front corner of the machine;

FIG. 8 is an isometric sectional view through the needle cylinder and the yarn guide rings and showing a portion of one type of open lace fabric produced on the machine;

FIG. 9 is Ia vertical sectional view illustrating the manner in which the pattern wheels are supported for adjustment and easy removal on the drive shaft therefor;

FIG. 10 is an enlarged vertical sectional view through the broken yarn detecting stop motion device of the knittingv machine, shown in the upper portion of FIG. 1;

FIG. 11 is a view of a portion of the creel taken substantially along the line 11-11.in FIG. 1 and illustrating the manner in 'which the yarn supply cones are supported and how pairs of cones may be tied together to provide continuous operation;

FIG. 12 is an enlarged sectional plan view taken substantially along the line 12-12 in FIG. 11 and illustrating the manner in which the yarns are withdrawn from the yarn cones and directed forwardly to the knitting machine by the creel;

FIG. 13 is an isometric view of a stocking :blank of the type `which is utilized to for-m tights or panty type garments and illustrating the tapered fashioning of the blank and the longitudinal slit which may be provided at the upper end;

FIG. 14 is a greatly enlarged, somewhat schematic representation of one type of open lace pattern fabric which may be knit, being that portion of the blank enclosed by the dotted rectangle 14 in FIG. 13;

FIG. 15 isa point-paper schematic diagram illustrating the manner in which the yarns are fed to the needles in knitting one repeat of the fabric shown in FIG. 14;

FIGS. 16-23 illustrate the various positions assumed by the yarn guides during `the simultaneous up and down movements of the needles to show the manner in which the yarns are fed to the needles;

FIG. 24 is an enlarged view of a modied type of open lace pattern fabric which may be knit;

FIG. 25 is a point-paper schematic diagram of the manner in which the yarns are fed to the needles in knitting one repeat of the fabric shown in FIG. 24;

FIG. 26 is an enlarged View of another modified type of open lace pattern fabric which may be knit; and

FIG. 27 is a point-paper schematic diagram of the manner in which the yarns are fed to the needles in knitting one repeat of the fabric shown in FIG. 26.

The machine includes a lower stand which supports the knitting machine frame 11. The frame 11 is preferraibly cast in one solid integral piece and is suitably attached to the stand 10. As shown in FIG. 5, the frame 11 is substantially rectangular in cross section and is preferably open at opposite ends.

An electric drive motor 12 is supported on the lower portion of the stand 10 (FIG. 1) and includes a drive pulley which imparts motion to a drive `belt 13, engaging a drive pulley 14 which is fixed on one end of a main drive shaft 15. The main drive shaft 15 extends through and is rotatably supported in opposite sidewalls of the frame 11 and one end may be provided with a suitable hand wheel, shown in dash-dot lines at 16 in FIGS. 4 and 5.

The opposite end of the main drive shaft 15 is provided with a drive pulley 17 (FIG. 2) which is engaged by a drive belt 18 to impart rotation to a drive pulley 19. The pulley 19 is fixed adjacent one end of a transverse drive shaft 20 (FIG. 4) which is rotatably supported in the frame 11. A drive pulley 21 is xed on the opposite end of the shaft 20 (FIG. 1) and is engaged lby a drive belt 22 which extends upwardly and around a drive pulley 23. The belt 22 is maintained in a tight condition by `a belt tightener roller 24 which is rotatably supported on one end of an adjustable bracket 25 on the outside portion of the frame 11 (FIG. l).

The pulley 23 is xed on one end of a cam shaft 26 (FIG. 4) which is supported for rotation in sutable bearing blocks 27, xed on the machine frame 11. The cam shaft 26 is adapted to support pattern means or pattern chains, to be presently described, and imparts rotation thereto in timed relationship to the operation of the machine.

The lower end of a slotted needle cylinder 30 is supported in a fixed, non-rotating position on an upper transverse portion of the machine frame 11 (FIGS. 6 and 7) and has latch needles 31 supported for vertical movement in the slots therein (FIG. 8). The needles 31 are preferably held in the slots by a removable spring band 32 which extends around the outer periphery of the shank portions of the needles 31 (FIG. 7).

The needles 31 are provided with lower operating butt portions 33 which differ from the usual needle butts in that they are rounded along the lower inner and outer portions, as shown at 33a in FIG. 8. This rounded lower portion 33a is provided to facilitate removal and replacement of the needles 31 in the needle cylinder 30. The needles 31 are simultaneously raised and lowered by a needle operating ring 34 which surrounds the needle cylinder 30 (FIG. 8) and includes a butt engaging groove 34a in which the butts 33 of the needles 31 are disposed. The upper inner portion of the ring 34 is beveled so that a needle may be easily replaced by removing the spring band 32 and outwardly rocking the upper end of the needle to be replaced. The tip of the butt 33 of the new needle may then be placed in the slot 34a and the upper end rocked inwardly into the vertical position so that the needle is securely connected to the ring 34.

As best shown in FIG. 5, opposite sides of the needle operating ring 34 are suitably secured to the upper ends of vertically disposed operating rods 35, 36. The upper portions of the rods 35, 36 are supported for vertical sliding movement in the upper horizontal portion of the frame 11 and the lower portions are supported for vertical sliding movement on the inner ends of guide support arms 37, 38 which are preferably formed integral with the inner surfaces of the frame 11. The lower ends of the operating rods 35, 36 are suitably secured to the outwardly extending portions of a yoke 40 that is adjustably secured to the upper end of an accentric 41. The eccentric 41 is fixed on the main shaft 15 and counterweights 42 are preferably provided on opposite sides thereof to balance the motion of the eccentric 41 as it is rotated at high speeds to thereby raise and lower the needles 31 in the needle cylinder 30.

As the tubular fabric, indicated at T in FIG. 6, is produced by the needles 31, in a manner to be presently described, it is drawn downwardly and flattened as it passes beneath an idler roller 45. The fabric T is drawn forwardly by a pair of fluted take-up rolls 46, 47 which are driven at a predetermined rate and in a manner to be presently described.

Means for periodically slitting the tubular fabric in a longitudinal direction is broadly indicated at 50 and means for transversely cutting the tubular fabric is broadly indicated at 51 in FIG. 6. The slitting means 50 is disposed between the roller 45 and take-up rolls 46, 47 and the cutting means 51 is disposed closely adjacent the output side of the take-up rolls 46, 47 and will be later described in detail.

A drive coupling sleeve 53 connects one end of the drive shaft 20 (FIG. 4) to the input shaft 54 of a variable speed drive mechanism 55. The variable speed drive 55 is suitably supported on the stand 10 and has an output shaft 56, on which a drive pulley 57 is supported. A belt 58 drivingly connects the drive pulley 57 to a drive pulley 59 which is fixed on one end of a positive yarn feed shaft 60. Opposite end portions of the shaft 60 are rotatably supported in bearings 61, 62 which are xed on the frame 11.

The medial portion of the shaft 60 is provided with closely spaced, V-shaped drive grooves which engage the warp yarns W as they are fed to the machine and Withdrawn from a yarn supply creel, to be presently described. Guide support arms 64 are fixed at their inner ends on the bearings 61, 62 (FIG. 4) and their outer ends are bent upwardly and support opposite ends 0f yarn guide rods 65, 66 (FIG. 3). Respective springs 67, 68 surround the guide rods 65, 66 and provide suitable spacing means for the warp yarns W as they approach and leave the yarn feed roll 60. The warp yarns W extend from the guide rod to the guide rod 66 (FIG. 3) and are wrapped one time about the grooved medial portion of the feed roll 60 to provide a positive feed to the yarns W.

A sprocket 70 (FIG. 4) is fixed on one end of the shaft 60 and is engaged by a chain 71 which imparts rotation to a sprocket 72 which is, in turn, fixed on one end of a front take-up shaft 73. The front take-up shaft 73 is supported for rotation in take-bearing stands 74, 75 (FIG. 4) and the upper take-up roll 46 (FIG. 6) is xed on the medial portion of the take-up shaft 73. Suitable meshing gears, not shown, in a gear housing 76 (FIG. 7) impart driving rotation to the lower feed roll 47 and suitable spring means, not shown, in the housings 74, 75 urge the lower take-up roll 47 into engagement with the upper take-up roll 46 so that the tubular fabric T is positively drawn therethrough in a attened condition and at a predetermined speed.

The take-up speed of the fabric and the feeding speed of the yarn may be varied, in a manner to be presently described, by the variable speed device 55. When the fabric take-up speed and the yarn feed speed are changed, relative to the speed at which the needles 31 are raised and lowered to form courses of stitches, the size of the stitch loops is charged so that the fabric tube is fashioned to vary the diameter of the tube being knit.

A pattern chain sprocket 80 is xed on the take-up shaft 73 and a pattern chain 81 is supported thereon for movement in timed relationship to operation of the machine. It is preferred that the pattern chain 81 make one cornplete revolution as each article blank is knit. The lower portion of the pattern chain 81 is directed around an idler sprocket 82 which is, in turn, supported on an adjustment arm 83. In the Ipresent instance, the pattern chain 81 is adapted to control the operation of the slitting means 50 (FIG. 6), the cutting means 51, and the position of a speed change control arm 84 on the variable speed device 55 (FIG. 2).

The speed change control arm 84 is normally drawn forwardly to a relatively fast speed position by a tension spring 85 (FIGS. 2 and 4). The rear end of a control link 86 is connected to the control arm 84 and the forward end is suitably connected to one end of a control lever 87 (FIG. 4). The control lever 87 is pivotally supported intermediate `its ends as at 88 and its other end is provided with a roller 89 which rides on the lefthand side` of the pattern chain 81 and aginst suitable pattern lugs 90.

The pattern chain 81 is shown in FIG. 2 in the position it occupies at the start of the knitting of a stocking blank with the roller 89 of the control lever 87 (FIG. 4) on a very low pattern lug 90. As the pattern chain 81 moves in a counterclockwise direction in FIG. 2, the lugs 90 progressively increase in height so that the control link 86 moves the control arm 84 rearwardly to gradually reduce the speed of the yarn feed shaft 60 and the take-up rolls 46, 47 so that smaller stitches are formed. As the size of the stitch loop is decreased, the diameter of the tubular fabric is reduced to fashion the blank, in the manner illustrated in FIG. 13. When the knitting of one blank is completed, the roller 89 moves from a high lug 90 to a loW lug and the control arm 84 is shifted back to the fast speed position so that the machine again forms long, loose or large stitches, at the start of the knitting of the next stocking blank.

As the tubular knit fabric T passes from the idler roller 45 (FIG. 6) to the take-up rolls 46, 47, it moves around an elongate flattened guide member 92 which is provided with a groove or slot in the medial portion of its lower surface. The slot is adapted to receive the upper corner of a blade 93 to, at times, form a longitudinal slit in the tubular fabric T. The blade 93 is preferably in the form of a safety razor blade and is suitably supported in one end of an operating arm 94. The other end of the operating arrn 94 is supported on one end of a stub shaft 95 Which extends through the sidewall of the frame 11 and has the lower end of an operating arm 96 fixed on the other end thereof.

The upper end of the operating arm 96 is provided with a follower roll 97 which rides against the right-hand race of the chain links of the pattern chain 81. A tension spring 98 resiliently maintains the follower roll 97 in engagement with the pattern chain 81 (FIG. 6) and normally holds the blade 93 in the solid line position and out of engagement with the tubular fabric T. As the follower roll 97 is engaged by raised cam lugs 99 (FIG. 6) the blade 93 is moved to the dotted line position and into the groove in the guide 92 so that a longitudinal slit is cut in the lower side of the flattened tubular fabric as it is drawn over the guide 92.

This longitudinal slit is indicated at S in FIG. 13 and is preferably formed at the proper time to cooperate with a transverse cut across the tubular fabric. To form the transverse cut, the tubular fabric T is guided over a fixed blade portion 100 (FIG. 6) as it leaves the take-up rolls 46, 47. A movable blade 101 is pivotally supported at one end on `the fixed blade 100 (FIG. 4) and its opposite end is suitably connected to a solenoid 102, which is operable to at times move the blade 101 across the fixed blade 100 and transversely cut the tubular fabric T. The movable blade 101 is normally urged to the outer inoperative position by a tension spring 103, one end of which is connected to the movable blade 101 and the other end of which is suitably supported on a bracket 104 lxed to the machine frame 11.

The operation of the solenoid 102 and the movable blade 101 is controlled by means of a switch 105 (FIG. 1), supported on the chain support arm 83 and positioned to be engaged by suitable pattern lugs, not shown, on the extreme left-hand portion of the pattern chain 81 which extend outwardly from the side thereof. When it is desired -to transversely cut the tubular fabric T, the switch 105 is closed at the proper time by a pattern lug on the pattern chain 81 to energize the solenoid 102 and pull the blade 101 across and in engagement with the fixed blade 100 to cut the tubular fabric T. As the plunger of the solenoid 102 nears. the end of its inward stroke (FIG. 4), the electrical circuit to the solenoid 102 is broken by a breaker switch 106 suitably sup-y ported on the solenoid 102 and the blade 101 is immediately returned to the open position by the spring 103. Recycling of the solenoid 102 is prevented by a relay not shown, until the pattern lug passes the switch 105.

The warp yarns W are withdrawn from a creel, broadly indicated at 110, which is supported on the floor, independently of and behind the knitting machine. Only the front portion of the creel is shown in FIGS. 1 and 11, 12, it being understood that a separate warp yarn is provided for each needle in the needle cylinder and in the present instance the machine is provided with 84 needles. The creel 110 includes a vertical support post 111 which has horizontally disposed support bars 112 connected thereto (FIG. 12) which support guide rods 113 having separator springs 114 supported thereon. From the support bars 112, the yarns are guided beneath a guide rod 115 (FIGS. l and 4) which is suitably supported at opposite ends in spaced relationship behind the machine frame 11 and is provided with a separator spring 116 which maintains the Warp yarns W in spaced alignrnent as they are directed toward the machine.

The creel 110 also includes horizontally disposed yarn support bars 118 which are provided with outwardly and upwardly diverging yarn support studs 119 (FIG. l1) adapted to support yarn supply packages P which are preferably wound on paper cones or tubes. Each warp yarn W is withdrawn from its corresponding supply package P and outwardly around a tension thread guide, such as illustrated at 120 in FIG. 12. The thread tension devices 120 are supported on horizontal frame members 121 and the warp yarns W from the rear supply packages, not shown, are guided forwardly to engage the guide rods 113 and then converge to pass beneath the guide rod 115.

The yarns W then are directed upwardly, over the guide rod 65, wrap the positive feed roll 60, beneath the guide rod 66, and then upwardly to a stop motion device spaced above the knitting machine and indicated broadly at 125 (FIGS. l and 10). As shown in FIG. l0, the warp yarns W are directed upwardly over a guide rod 126, which is provided with a separator spring 127 and then over a pair of spaced guide rods 128, 129. Each warp yarn W supports a drop wire 130 which is maintained in the position shown in FIG. l0 and out of engagement with an electrical contact element 131 as long as the drop wire 130 is supported by the warp yarn W. Should one of the warp yarns break or become excessively slack, the drop wire 130 will drop down and engage 7 the contact element 131 to thereby stop the electric drive motor 12 and knitting machine.

As the warp yarns W leave the guide rod 129, they are divided into two groups W-1 and W-2 and pass over respective guide rods 132, 133 which are provided with suitable separator springs 134, 135. The stop rnotion device 125 is supported in spaced relation above the knitting machine (FIG. l) on the upper end of a vertical support post 137, the lower end of which is connected to the stand of the machine.

The groups or sets of warp yarns W-l and W-2 are directed downwardly from the stop motion device and to yarn guide ring means which includes at least an upper guide ring (FIG. 8) and a lower or bottom guide ring 142. The inner edge of the guide ring 140 is provided with vertical yarn guide holes 143 which correspond in number and spacing with the needles 31 in the needle cylinder 30. The holes 143 are spaced closely adjacent the inner peripheral edge of the guide ring 140 and, as shown in FIG. 8, the yarns W-1 are threaded through every other hole 143 in what will be referred to as a one in, one out arrangement. The outer peripheral edge of the ring 140 is beveled on both the upper and lower sides, as indicated at 144 to provide means to oscillatably support the ring 140 in a plurality of support rollers 146. Three rollers 146 are shown in FIG. 7 and they are each provided with V-shaped grooves to mate with the outer peripheral edge of the upper guide ring 140. The rollers 146 are supported on the upper end portion of support posts 147 by means of adjustment brackets 148 and the lower ends of the posts 147 are xed in the machine frame 11.

The lower yarn guide ring 142 is provided with an inner upstanding edge portion 150 and horizontal yarn guide holes 151 which correspond in number and spac- Y ing with the needles 31 in the needle cylinder 30. The lower portion of the lower guide ring 142 is tapered at its inner peripheral edge, as at 152 (FIG. 8), and serves as a latch opening guard when the needles 31 are raised during each course of knitting, in a manner to be presently described.

The set of warp yarns W-2 is split into three groups and directed downwardly and beneath separator guide springs 154 (FIG. 7) which are supported at opposite ends on the upper surface of the lower guide ring 142. The yarns W-2 are directed downwardly and pass between the coils of the spring 154 (FIG. 8) and move along a horizontal path as they move to and through the horizontally disposed yarn guide holes 151. As the yarns W-2 pass downwardly from the horizontally disposed yarn guide holes 151 and to the needles 31, they are positioned outside of the yarns W-1 substantially as shown in FIG. 8. In order to properly feed the sets of yarns W-1 and W-2 to the needles 31, it is necessary to oscillate the yarn guide rings 140, 142 in the proper timed relationship, relative to the raising and lowering of the cylinder needles 31 in order to produce the desired type of pattern in a tubular fabric.

The outer peripheral edge of the lower guide ring 142 is beveled, as at 155 (FIG. 8) and is supported for oscillation in rollers 156 having mating grooves therein (FIG. 7). Three rollers 156 are shown in FIG. 7 and they are each supported in a bracket 157 which is adjustably secured to the upper portion of the support post 147. Oscillationsare imparted to the upper guide ring 140 and the lower guide ring 142 by means of respective control links 160, 162, the forward ends of which are suitably connected to the respective rings 140, 142 (FIG. 7) and the rear ends of which are connected to the upper ends of bell crank arms 163, 164 which are fixed at their lower ends on respective stub shafts 165, 166. The stub shafts 165, 166 are supported in bearing blocks 167, 168 and the lower ends of corresponding bell crank levers 170, 171 are connected to the stub shafts 165, 166. The upper ends of levers 170, 171 are provided with respective cam rollers 170a, 171:1 which are resiliently urged into engagement with pattern means, illustrated as respective pattern cam wheels 173, 174. The rollers 17051, 171a are resiliently urged against the cam wheels 173, 174 by tension springs 175 (FIG. 2).

Thus, the sinuous shape of the peripheral surface of the cam wheels 173, 174 determines the timing 'and amount of movement or oscillation imparted to the respective upper and lower yarn guide rings 140, 142 to thereby control the manner in which the yarns are fed to the hooks of the cylinder needles 31. While pattern cam wheels are illustrated at 173 and 174 for controlling the oscillation of the yarn guide rings 140, 142, it is to be understood that pattern chains forming a sinuous cam surface could be utilized in place of the cam wheels 173, 174. The pattern chains could extend down inside of the frame 11 and, if of sufficient length, could extend out the rear of the frame 11 and down beneath the machine, if necessary.

In order to provide adjustment and easy removal, the pattern Wheels 173, 174 are supported on the pattern shaft 26 (FIG. 4) by means of adjustment locking sleeves, such as illustrated at 176 in FIG. 9. The sleeve 176 is split at its inner end and has a long gradual taper which fits against the inwardly tapered inner peripheral surface of a hub 177 to which the pattern cam wheel is suitably attached. Screws 178 are utilized to draw the tapered hub 177 onto the sleeve 176 and cause the inner split portion of the sleeve 176 to tighten against the pattern shaft 26.

METHOD OF OPERATION A wide variety of different patterns may be produced with the machine of the present invention. One preferred type of fabric pattern to be described will be referred to as a honeycomb pattern. A portion of this pattern is illustrated as it is being drawn down the needle cylinder 30 in FIG. 8 and it is schematically illustrated in a relaxed condition in FIG. 14. This pattern comprises sixsided openings which are staggered in a vertical direction and opposite sides of each opening are formed of two-needle walewise extending stitch chains, indicated at C in FIG. 14. The two-needle stitch chains C are interconnected by diagonally extending single-needle stitch chain portions K.

In this particular honeycomb pattern, ten courses are required for each repeat of the pattern, as indicated at C-1 through C-10 on the point-paper layout illustrated in FIG. 15. The machine is set up so that the pattern cam wheels 173, 174 make one revolution while the needles 31 are raised and lowered to knit ten courses. The manner in which the yarn guide rings 140, 142 are shifted relative to the needles 31 is illustrated in FIGS. 16-l9 and stitches are shown on needles 3 and 4 only. To aid in the description, the needles are numbered 1-4 in FIGS. 15-23.

Assuming that the needles have been lowered to knit the course C-l and the yarns W41 have formed stitch loops on the needles 1 and 3 while the yarns W-2 have formed stitch loops on the needles 2 and 4, the parts will be in the position shown in FIG. 16. As the needles 31 raise to the upper position shown in FIG. 17, the rings 140, 142 oscillate in opposite directions a distance of one needle space. With downward movement of the needles 31, the rings 140, 142 shift in opposite directions a distance of about three needle spaces so that when the needles are about half-way down in their stroke, as shown in FIG. 18, the yarns W-Z are inclined to the left a sucient amount to be caught in the hooks of the needles 1 and 3 while the yarns W-1 are inclined to the right a suflicient amount to be caught in the hooks of the needles 2 and 4. As the needles move on down to stitch forming level (FIG. 19), the yarns W-2 form stitch loops on the needles 1 and 3 (FIG. 19) While the yarns W-1 form stitch loops on the needles 2 and 4.

Thus, the sets of yarns cross between the knitting of courses C-1 and C-2 so that the yarns W-l form stitches on the needles 1 and 3 in course C-l and then form stitches on the needles 2 and 4 in course C-2 while the yarns W-2 form stitches on the needles 2 and 4 in course C-1 and then form stitches on the needles 1 and 3 in course C-2. This crossing action of the yarns forms the walewise extending two-needle stitch chain C with the two wales being interconnected after each stitch (FIGS. 14 and 19).

During the knitting of the next courses C-3 and C-4, the guide rings move in the same manner but in opposite directions to continue the formation of-the twoneedle stitch chain, as illustrated in FIG. 15. In tcourses C-4 and C-5, the respective yarns W-l and `W-Z are knit on the same corresponding needles 2, 3l` without crossing each other and the upper and lower guide rings 140, 142 are shifted or shogged in the manner illustrated in FIGS. 20-23. Knitting on the same needles in courses C-4 and C-S produces the single-needle angularly extending stitch chains K (FIGS. 14 and 23).

Following the knitting of course C-4, the upper guide ring 140 is shifted to the right (FIG. 20) and the lower guide ring -142 is shifted to the left. As the needles reach the top of their stroke (FIG. 21), the guide rings 140, 142 begin to move back in the opposite direction so that they reverse positions as the needles are loweredi (FIG. 22) and the yarn W-1 is wrapped about the needle 2 while the yarn W-2 is 'reversely wrapped about the needle 3. When the needles are lowered to stitch forming position to form course C-S (FIG. 23), a stitch is again knit of yarn W-1 on needle 2 and a stitch is again knit of yarn W-Z on needle 3 to form separate singleneedle connector stitch chains. In the courses C`6 through C-9, the yarns W-1, W-2 are successively crossed between adjacent needles so that the yarns connect together the two-needle stitch chain formed on the needles 2 and 3 (FIG. 15). To accomplish this, the upper and lower guide rings 140, 142 are shifted in a manner similar to that illustrated in FIGS. 16-19; however, the yarns are crossed between different needles; i.e., needles 2 and 3 instead of the needles 1, 2 and 3, 4, as was the case during the knitting of courses C-1 through C-3. l

As pointed out above, the guide rings 140, 142 are moved during both upward and downward movements of the needles. Thus, the sinuous cam surfaces of the wheels 173, 174, through the corresponding followers and linkage, impart substantially uninterrupted and continuous movement to the guide rings while the needles are being continuously raised and lowered by means of the eccentric cam -41 so that a substantial portion of each cycle'of'movement of the needles is utilized to move the guide rings 1-40, 142 between extreme positions in each direction. This continuous and uninterrupted movement of the guide rings 140, 142 during the up and down movements of the needles thereby permits utilization of the time lag between movement of the needles between their extreme upper and lower positions and thereby permits the machine to be operated at the high speeds heretofore mentioned.

By varying the shogging of the yarn guides and/or merely by changing the threading of the yarns in the two yarn guide rings, it is also possible to obtain a wide range of other different types of patterns. For example, a pattern referred to as a mini-square is schematically shown in FIG. 24 and in the point-paper layout of FIG. 25. In knitting this pattern, the upper and lower guide rings are each threaded one in, one out, and a repeat is formed with each ten courses, as illustrated from C-1 through C-10 of FIG. 25. In this knitting procedure, the yarns W-1 and W-2 cooperate to form interconnected two-needle stitch chains on adjacent pairs of needles, such as needles 1, 2 and 3, 4, up through course C-4. The yarns W-l, W-Z cross before course C-S so that during courses C-5 through C-9, the yarn W-l (which had previously knit on needles 1, 2) then alternately knits on the needles 3, 4- and the yarn W-2 (which had previously knit on needles 3, 4) then alternately knits on the needles 1, 2. As the yarns W-1 and W-2 cross (after courses C-4 and C-9), the two-needle chain stitches C are joined together by horizontal floats at spaced apart positions, as indicated by the letter F in FIG. 24.

A regular diamond or shnet pattern is schematically illustrated in FIG. 26 in the point-paper layout of FIG. 27. To form this pattern, the upper and lower guide rings are each threaded with the one in, one: out arrangement. As shown in FIG. 27, the pattern is a ten course repeat and the guide rings successively feed their yarns W-1, W-2 to the same needles 1, 3 and 2, 4 to form single-needle stitch chains R through course C-4. The yarns are crossed after courses C-4 and C-S to join the stitch chains formed on needles 2, 3. Stitch chains are again formed on needles 2, 3 in courses C-6 through `C-9 and the yarns are again crossed after courses C-9 and C-10 to join the stitch chains formed on needles 1, 2 and 3, 4 so that the stitch chains are alternately joined to adjacent chains to produce the diamond configuration shown in the fabric of FIG. 26.

Many diiferent types of patterns may be knit by changing the shogging movements of the guide rings 140, 142. Different patterns may also be obtained merely by changing the threading of the yarns in the holes of the guide rings. For example, the shogging movement applied in making the regular diamond pattern (as shown in FIGS. 26 and 27) may also be used to make a pattern having a different appearance by simply threading the upper guide ring with three yarns in and one yarn out while threading the lower yarn guide ring one in, one out. This produces a diamond pattern with distinctive walewise stripes of heavier stitch chains and a closely spaced `zig-zag chain on each side of the heavier wale. It is also to be understood that more than two yarn guide rings may be utilized, if desired.

`Other attractive and unusual patterns may also be produced by feeding different types or colors of yarns to the knitting machine. For example, various walewise or zig-zag stripes may be produced by feeding yarns of different colors or yarns of various sizes may be fed to the machine to form walewise extending thick and thin fabric areas. This is possible in the present machine because of the separate yarn creel where each yarn end is withdrawn from its own supply package. Also, some stretch yarns may be fed while some non-stretch yarns are fed. These various thread feeding arrangements would not be possible on machines where the warp yarns are fed from warp Ibeams.

If it is desired to form ladies stockings of the tubular open lace fabric produced on the machine, a thermoplastic stretchable multilament yarn is preferably used and the slitting `means 50 (FIG. 6r) is disconnected. Then, the cutting means 51 is set to cut the tube after the desired length is knitl and the fashioning means is controlled to gradually vary the size of stitch being formed throughout the length of each blank. The stocking blanks are then finished in the usual manner after the toe end is closed, as by sewing, and the upper end is finished by sewing or attaching a welt portion thereto.

When the blanks are to be formed into tights or leotard type garments, the slitting means 50 operates to form a slit, as shown at S in FIG. 13, at one side of the top. The lower toe ends of the blanks are closed and the slit inner edges are joined together to form a body portion. The inner slit edges can either be directly joined to corresponding edges of an adjacent blank to form a single seam extending from the front edge to the rear edge and through the crotch, or the corresponding slit edge portions can be connected to opposite edges of a center crotch panel, not shown. In some cases, it may be desirable to provide a crotch panel which extends from the upper front to the upper rear of the body portion or it may extend up only a small distance in the front and rear.

The positive feed of the yarns by the shaft 60 and the positive take-up by the rolls v46, 47 provides means to accurately control the fashioning of the tubular fabric being knit. In order to more accurately control the feed of the yarn it may be desirable to wrap the Warp yarns two times around the shaft 60. The V-shaped drive grooves on the shaft 60 are preferably rounded at their top and bottom portions and the angle of travel of the incoming yarn and the yarn leaving the shaft 60 may be offset about 20' degrees to prevent any possible overlap of the yarn as it goes onto and leaves the grooves of the positive feed shaft 60.

Whilethe present machine has been described in conjunction with the knitting of tubular fabric, it is to be understood that this machine may also knit iiat fabric. For example, a fiat fabric may be knit on this machine by removing a needle and/or by threading the guide rings so that yarn is not fed to one of the needles. In some patterns it may be desirable to thread the yarns in such a manner that thickened selvages are formed.

In the drawings and specification there have been set forth preferred embodiments of the invention and although specic terms are employed, they are used in a generic and descriptive sense onlly and not for purposes of limitation, the scope of the invention being defined in the claims:

We claim:

1. A circular warp knitting machine adaptable to knit seamless tubular fabric, said machine having a frame and comprising (a) a needle cylinder supported in a non-rotating position on said frame,

(b) needles supported for vertical movement in said cylinder,

(c) means for simultaneously raising all of said needles to yarn receiving position and then simultaneously lowering said needles to stitch drawing level in a continuously repeating manner,

(d) yarn guide means supported above said needles and in alignment with said needle cylinder for guiding a separate yarn to each corresponding needle,

(e) positive take-up means for withdrawing the knit tube at a predetermined rate,

(f) positive yarn feeding means for feeding the yarns to the needles at a predetermined rate relative to the fabric take-up rate,

(g) common drive means including variable speed means for said positive take-up means and said positive yarn feeding means, the speed of said common drive means determining the size of the knit stitch loops, and

(h) pattern means for selectively controlling said varable speed means to thereby vary said predetermined rate of yarn feed and said fabric take-up during the knitting of selected portions of the tubular fabric.

2. A circular warp knitting machine for knitting a continuous seamless tubular fabric of the type suitable for forming stockings therefrom, said machine having a frame and comprising (a) a needle cylinder supported in a non-rotating position on said frame,

(b) needles supported for vertical movement in said cyflinder,

(c) means for simultaneously raising all of said needles to yarn receiving position and then simultaneously lowering said needles to stitch drawing level in a continuously repeating manner,

(d) yarn guide means above said needles and in alignment with said needle cylinder for selectively guiding yarns to said needles,

(e) slitting means selectively operable at predetermined intervals to longitudinally slit one side of the knit tube for a predetermined llength, and

(f) severing means operated in timed relation to said machine for transversely cutting the knit tube at intervals corresponding to the operation of said slitting 12 means to form stocking blanks of the desired length and having a slit extending inwardly from one end.

3. A knitting machine according to claim 2, including positive take-up means comprising a pair of driven takeup rolls between which the knit tube is drawn, and wherein said slitting means comprises an elongate guide member positioned inside the knit tube and constrained against movement in the direction of movement of the knit tube by the entrance side of said take-up rolls, said guide member having a longitudinal groove therein, a slitting blade supported adjacent said guide member and being operable by said pattern means to move into the groove of said guide member in timed relation to operation of said severing means to longitudinally slit the knit tube.

4. A circular warp knitting machine comprising (a) a needle cylinder having needle supporting s'lots around the outer periphery thereof,

(b) needles supported for vertical lmovement in the slots of said cylinder,

(c) means for simultaneously raising all of said needles to yarn receiving position and then simultaneously lowering said needle to stitch drawing level in a continuously repeating manner,

(d) yarn guide means positioned above said needles and in alignment with said needle cylinder, said yarn guide means including at least one yarn guide ring,

(e) Vmeans supporting said yarn guide means for oscillation in a horizontal plane to guide yarns to the needles, said support means including a support member with a V-shaped groove mating with and supportingly engaging the outer peripherall edge of said guide ring, and

(f) control means for imparting uninterrupted and continuous oscillation to said guide means during both upward and downward movements of said needles to thereby permit high machine operational speeds by utilizing a substantial portion of each cycle of movement of the needles to move said yarn guide means between extreme positions in each direction.

5. A circular warp knitting machine according to claim 4, including a needle actuating ring surrounding said needle cylinder and being operatively connected to said needles, and wherein said means (c) includes (l) a drive shaft supported in spaced relationship below the center of said needle cylinder,

(2) an eccentric ixed on said drive shaft,

(3) means operatively connecting said eccentric and said needle actuating ring for imparting vertical movement to said needle actuating ring and the needles operatively connected thereto, and

(4) counterweight means carried by said shaft and adjacent said eccentric for balancing the motion of the eccentric as it is rotated at high speeds.

6. A circular warp knitting machine according to claim 4, wherein said support means (e) consists of three substantially equally spaced apart support members.

7. A circular warp knitting machine comprising (a) a fixed needle cylinder having needle supporting slots around the outer periphery thereof,

(b) needles supported for vertical movement in the slots of said cylinder,

(c) means for simultaneously raising all of said needles to yarn receiving position and then simultaneously lowering said needles to stitch drawing level in a continuously repeating manner,

(d) yarn guide means positioned above said needles and in alignment with said needle cylinder for guiding yarns to the needles, said yarn guide means including at least one guide ring having inner and outer peripheral edges and yarn guide openings adjacent the inner peripheral edge thereof, the outer peripheral edge of said guide ring being beveled on both the upper and lower sides,

(e) means supporting said guide ring for oscillation in a horizontal plane, said support means consisting E three substantially equally spaced apart support members supportingly engaging the outer peripheral edge of said guide rings, said support members each including a V-shaped grooved portion mating with and supportingly engaging the outer peripheral edge of said guide ring,

(f) pattern control means for oscillating said yarn guide ring in timed relationship to vertical movement of the needles.

References Cited UNITED STATES PATENTS 205,663 7/1878 McNary 66-81 XR 386,272 7/1888 Sibley 66-132 XR 770,633 9/ 1904 Folsom 66--147 960,755 6/ 1910 Wildman 66-147 1,005,720l 10/1911 Lawrence 66-81 1,201,803 10/1916 Chace 66-195 1,524,388 1/ 1925 Campbell 66-147 1,649,126 11/ 1927 Ratignier 66-81 1,828,878 10/ 1931 Seifert 66--81 1,855,033 4/ 1932 Spiers.

. 14 1,869,304 7/1932 Decker et al. 1,998,473 4/ 1935 Welch et al 66-8 2,447,103 8/ 1948 Susen 66-147 XR 670,497 3/ 1901 Hill 66-81 FOREIGN PATENTS 2,013 4/ 1946 France. 146,510 12/1881 France. 828,578 1/ 1952 Germany. 12,195 1848 Great Britain. 23,650 1903 Great Britain. 985,666 3/ 1965 Great Britain. 1,036,246 7/ 1966 Great Britain.

46,023 9/ 1962 Poland. 15

OTHER REFERENCES WM. CARTER REYNOLDS, Primary Examiner U.S. Cl. X.R.

Images