Note: Descriptions are shown in the official language in which they were submitted.
This applica~ion is a division of application Serial
Number 300,566 :filed April 6, 1978.
Definitions
The following definitions shall be applicable
herein:
The terms "sliver feeding dPvice" and "card" are
synonymous, and indicate the conventional means for feeding
a sliver or roving to the needles of a high pi:Le fabric
knitting machine.
The term "feeding station" indicates a single
location on a knitting machine where sliver fibers and yarn
are, or may be, fed in succession to the needles of the
machine. The term "~eeding s~r-ltlon" shall be applicable
to indicate such a location where sliver fibers only J with-
out yarn, are fed to the needles of the machine, a~ in
knitting pattern work.
The terms "stitch" and "knitted stitch" are
synon~nous, and indicate a loop of yarn which has been pulled
through a preceding yarn loop.
The term "casting off" indicates the discharge of
a loop of yarn from a needle, as a newly drawn loop of yarn
is pulled through the discharged loop to folm~a new stitch.
The term "cast-off level" indicates the lowest
level to which a needle descends in casting off a stitch or
yarn loop.
The terms 'Iclearing level" and "clear" indicate
the level to which a needle rises, or has risen, to clear
yarn from its latch, preparatory to receiving a new yarn in
its hook.
--2--
/
The terms "course-wise" and "course-wise extending"
are directional terms indicating the "horizontal"
dimension extending along a course of a knitted fabric.
The terms "wale~wise" and "wale-wise extending" are
directional terms indicating the "vertical" dimension
extending along a wale of a knitted fabric.
The term "interlaced" refers to sliver fibers which
are not incorporated into the fabric in the form of
knitted stitches/ but rather have been incorporated into
the fabric in the form of floats extending diagonally
across at least two courses and two wales of the fabric.
The interlaced fibers are manipulated between and about
the needles during knitting in such manner that, when the
needles descend to cast-oEE level, those fibers are cast
over the needles and are incorporated into the Eabric as
floats.
Background of the Invention
Sliver knitting, wherein sliver fibers and yarn are
fed to the needles of a knitting machine to knit pile
fabric, is an old art, tracing its origin back to United
States patent No. 1,114,414. The knitting mechanism
usually comprises a circu]ar jersey fabric knitter
equipped with a plurality oE cards for Eeeding sliver
fibers to the needles of the knitting mechanism.
Generally, in sliver knitting, a single-faced high pile
fabric is produced, comprising a base fabric anchoring
tufts of sliver fibers, the free ends of which project
from one side of the fabric. Each tuEt is of generally
~-shaped configuration and is composed of a plurality of
staple fibers interlooped with the stitches of the
--3--
fabric. Such a fabric is ill~strated, for example, in
United States patent No. 3,226,952, which utilizes air
nozzles located externally of the needle cirele to blow
the free ends of the tufts under the sinker nibs, to
position the tufts selectively Oll the needles during
knitting.
Since the inception of sliver knitting, numerous
attempts have been made, with little or no commercial
success, to produce sliver knit fabrics which depart ~rom
the single-faced high pile type. Two-faced pile fabrics
have been proposed, as illustrated in United States
patents Nos. 2,712,225, 2,725,735, 2,953,912 and 3,021,698.
In patent 2,953,912, succ~ssive, opposikely disposecl air jets
ar~ utili~ed to produce a two-f~lcecl h:igh pile fabric. The
opposi~ly disposed air j~ts ~Ire mounte(l ~cljnc~nt alt~rnat-
ing cards s~lcod clround th~ nc~dl~ circl~.
Atte~pts have been made to produce sliver loop
knit fabrics in the past utilizing conventional sliver
knitters. Such attempts are illustrated by United States
patents 2,255,078, 2,280,536 and 2 J 457,104. So far as
presently is known, such endeavors have not proved to be
successful in practice. In patents 2,255,078 and 2,280,536,
angularly spaced rotary brushes, disposed to engage ~he
needles, are proposed to brush the free ends of sliver fibers
held by the needles first outwardly and then inwardly between
the needles, to produce a two-faced sliver knit fabric. In
patent 2,457,104 suction means~ disposed adjacent the needles,
is utilized to draw the free ends of sliver fibers held by
- the needle outwardly of the needle circle, whereby the free
ends of the pile fibers project from what normally is the
-; rear plain face of the fabric.
: Summary of the Invention
The primary object of this invention is to provide
method and apparatus for knitting a new and improved sliver
loop knit fabric.
In one aspect the invention provides a met}-lod of
making sliver loop knit fabri.c on a knitt:ing machine having
a circle of latch needles and sinkers and a plurality of
:~ sliver and yarn feeding stations spaced about the circle of
needles and sinkers, comprising the steps: (a) feeding sliver
fibers and yarn to the needles~ (b) manipulating the need.les
and sinkers to form the yarn and sliver fibers into a base
fabric having knitted stitches incorporating tufts of sliver
fibers, said tuI.`ts having free encls extend:i.ng from stitches
on ancl :immeclicltely acljacent to the needl.es, (c) blowi:ng the
: ~rec ends o~ the -tu:Ets diagorlcl}.ly outwardly relative to the
needle circle and downwardly onto the tops of the sinkers by
jets of compressed air after the needles have begun to ascend
from cast-off level and (d) incorporating the outwardly ex-
tending free ends o-f each o:E -the tu.fts into plural courses
and plural wales of the fabric by knitting and interlacing,
whereby the sliver :Eibers extend diagonally course-wise and
walc-wisc of the fabric.
The invention also provides a me-thod of making
sliver loop kni.t :Eabric on a knitting machine having a circle
of alternating latch needles and sinkers and a plurality of
sliver and yarn feeding stations spaced about the circle of
needles and si.nkers, comprising the steps: (a) feeding sliver
fibers and yarn -to the needles, (b) manipulating the needles
and sinkers to form the yarn and sliver fibers into a base
- 30 fabric having kni-tted stitches incorporating tufts of sliver
:Eibers, said tufts havi3lg free ends ex-tendi.ng from st:itches
on and immediately adjacent to the needles (c) blowing the
free ends of the tufts outwardly of the needle circle and
downwardly onto the tops of the sinkers by jets of compressed
air after the needles have begun to ascend from cast-off level
said free ends bei.ng blown diagonally outward at an angle
relati.ve to the needle circle sufficient to cause the out-
wardly extending free ends to traverse at least the sinker
next succeeding each needle and (d) incorporating the
outwardly extending free ends of each of the tufts into
plural courses and plural wales of the fabric whereby the
sliver fibers extend diagonally course-wise and wale-wise
of the fabric.
The invention also relates to a m~thod o:f mak:ing s:l.;.ver
I.oop knit fabr:i.c on a kn:it-ting machine havi.ng a ci:rcle o:f
latch nee(lles an(l sinkers allcl a p:lurality o:E sl:iver ancl
yarn feeding stations spaced about the circle of needles
and sinkers comprising the steps: (a) feeding sliver fibers
and yarn to the needles (b) manipulating the needles to cause
the needles to descend to case-off level to :Eorm the yarn and
:- 20 sliver fibers into knitted st:itches incorporating tufts of
sliver fibers said tufts hav:ing free ends extending from
said stitches (c) man:ipulating the needles to cause the
needles to ascend fxom case-off level to clearing level
with incidental opening and clearing of their latches (d)
blowing the free ends of the tufts diagonally outwardly in
. the same direction relative to the needle circle and down-
wardly onto the tops of the sinkers by jets o:f compressed
air after the needles have begun to ascend from case-off
level and (e) incorporating the outwardly extending free ends
of each of the tufts into plural courses and plural wales
of the fabric by knitting and interlacing l~hereby the sliver
-- 6
fibers extend cli.agonally course-~iise and wale-wise of the
.~ fabric.
In its apparatus aspect, the invention provi.des in a hig}
pile :Eabric knitting machine having a plurality of s:Liver
ancl yarn feeding stations ancl a circle of alternating latch
needles and sinkers -Eor forming sliver fibers and yarn into
knitted fabric having course-wise and wale-wise e~tending
stitches, the improvement compIising fiber manipu].ating means
for incorporating each of plural tufts o-f sliver fibers into
plural courses and plural wales during knitting, whereby said
sliver fibers extend both course-wise and wale-wise o:E the
-fabric to prov:ide a sliver loop kni.t :~`abr:ic, saicl fi.bel
man:ip-llatillg means compr:isi:ng: (a) the neeclles, (b) si.nke~rs
adapted to be aclvclrlced re:lcLt:i.ve to the neeclle circle to push
sliver fibers inwardly of the needle circle and (c) pneuma-tic
means for directing compressed air in the direction oE the
. needles to blow the sliver fibers diagonally outward o-E the
- needle circle and downwardly onto the tops of the sinkers,
(d) said pneumatic means being stationary relative to the
needles ancl comprisillg at least one air je-t disposed inter-
mecliate adjclcent sliver and yarn leeding stations, each saicl
air jet being located i.nternally of and adjacent to the
needle circle at a location pro~imate to and trailing a
position on the needle circle where the needles reach
~ cast-off level, (e) each said ai.r jet being disposed to blow
.. the sliver fibers diagonally outward at an angle relative to
the need].e ci.rcle.
Preferably, a sliver high pile fabric circular knitting
machine is utilized, of the basic type illustrated in
U.S. Patent l,ll~ . rhe maclllne comprises a jersey
.,'
';
~ ~f~
fabric knitter provided with a plurality of angularly spaced
sliver and yarn feeding stations. Disposed between successive
or adjacent feeding stations are one or more a;r jets, each
air jet being disposed interilally of the needle circle and
being adapted to direct a stream of compressed air in the
direction of the needles.
As the needles ascend from cast-off level, the
compressed air jets blow the free ends of the tufts of
sliver fibers held on the needles, as well as the free cnds
of the tufts anchored by one or more adjacent cast-off
stitches, outwardly of the needle circle, between the needles,
onto t]le tops of the sinkers surrounding the needles. The
sevcral tufts are blo~n so th~ir Eree ends are millgled
togctller to Eor~ slleet or web of fibers extending diagorlally
out~LIl~d rclative ~:o both -the sinkers ancl the needle latc]les.~
As the needles contillue their ascent to clearing level, their
open latches engage and retain most of the outwardly extend-
ing fibers. W}lell thc needles subse~uently descend to
cast-off level, their latches are closed to trap under the
needle hooks the outwardly extending fibers retainecl on the
latches, preparatory to forming the trapped fibers into
knitted stitches.
During the ascent oE thc ne~edles to clearing level,
the usual reciprocable sinkers have been advanced fully to
web holding position. When the sinkers advance, they push
: the outwardly extending mass of fibers, including the stray
sliver fibers not trapped by the needle latches, inwardly of
the needle circle. The sinkers interlace the free ends of
tlle stray fibers around the needles, below their latches.
When the needles descend to cast-off level, -the s-tray sliver
fibers are interlaced into the fabric in the form of floats.
~he above-described kni-tting and interlacing of ~he free ends
o-f the sliver fibers incorporates the fibers into plural
courses and plural wales o:E the fabric~ to provide a sliver
loop knit :Eabric generally similar -to loop pi.le fabric.
Other objects and advantages of this invention
will be readily apparent :From the following description of
preferred embodi.ments thereof, reference being had to the
accompanying drawing. Claims to the fabric are con-tained in
the parent application.
Description oF the Views o:E the Drawing
1 0 _ , _
Fig. 1 is a diagrammatic view in top plan showing
the ]cnitting head o:E a muIti-~eed sliver high pile :fabric
C irC-II.lr ]Clli. tt-ing mclch-ine.
Iig. 2 is a fragmentary, diagrammatic view in
perspective showing the outside of a sliver loop knit fabric
embodying this invention.
Fig. 3 is a fragmentary, diagramma-tic view in
perspecti.ve showi.ng an alternate :Eorm of sliver loop knit
; fabric embodying this inventio~
Fig. 4 is a :Eragnlclltclry view i.n top pla.n showing
schematiccll].y the knitting heacl o.F a mod:iFication of the
I'ig. 1 knitting machine, ill.wstrating the machine components
in more detail than Fig. 1.
33
Fig. 5a is an enlarged, fragmentary, diagrammatic
view in linear development, taken externally of the needle
cylinder of the machine of Fig. 4, showing in elevation the
needles, sinkers, yarns, yarn tubes and ,air jets in their
relationship to each other, for knitting the fabric of Fig. 2.
Fig. 5b is a plan view complementary to Fig. 5a,
showing in linear development the sinkers illustr.ated in
Fig. 5a.
Fig. 6 (with Fig. 1) is a fragmentary vertical section
~ 10 ~aken transversely of one of the sliver feeding devices o-f the
- machine of Fig. 4, illustrating the feeding of sliver fibers
by a doffer to the needles of the machine.
Fig. 7 is an enlarged, fragmentary view in elevation
- .illustrating a needl~ at cast-off level.
Fi.g. 8 is an enlarged, frag~entary view in elevation
illustrating a needle in the process o ascending from cast-
off level.
; Fig. 9 is an enlarged, fragmentary view in elevation
illustrating a needle which has risen to clear level, and is
in the process of taking yarn in its hook.
Figs. lOa and lOb are linear developments similar
to Figs. Sa and Sb, respectively, showing the arrangement for
knitting the Eabric of Fig. 3.
Detailed Description o-f E:mbo~liments of the Invention
In Fig. 1, there is shown diagrammatically in top
plan the knitting head of an open top multi-feed sliver high
pile fabric circular knitting machine 10 to which this inven-
tion has been applied. Although the machine 10 ~ay be equipped
- 10 -
. .
1579-/6
with four, eight, twelve or fourteen sliver and yarn feeding
stations, for the purpose of illustration the ~achine is
shown provided with eight feeding stations, Fl to,~ inclusive,
spaced uniformly about the circle of needles. The needles
are of the conventional independent latch type J mounted in
the usual rotatable needle cylinder. The need'Le cylinder
and its complement of needles rotate in the direction indi-
cated by the curved arrow in Fig. 1.
Each of the eight circumferentially or angularly
spaced feeding stations Fl-F8 includes, respectively, a
conventional card Cl, ~2, etc., and yarn feed Yl, Y2, etc.
A second yarn eed Y'l, Y'2, etc., may be disposed inter-
mediate adjacent or successive slivcr and yarn feeding
stations. Each yarn feed Yl, Y'l, Y2, Y'2, etc. comprises
a yarn tube disposed adjacent to the needle circle, for
delivering yarn to the needles. '~
In the embodiment illustrated diagra~matically in
Fig. 1, a pair of angularly spaced air jets or compressed
air nozzles Al, A'l, A2, A'2, etc., are disposed between
adjacent feeding stations Fl, F2, etc. The several air jets
are located inside the needle circle, and positioned to
direct streams of compressed air outwardly of the needle
circle, in the direction of the needles. The air jets may
be provided with valves V to adjust and control the amount
of compressed air discharged from their nozzles~ selectively
as desired, during knitting.
Each of the first air jets Al, A2, etc., is spaced
angularly, in the direction of needle rotation, from a yarn
feed Yl, Y2, etc. Similarly, each of the second air jets
- 11 -
A'l, A'2, etc., is spaced angularly, in the direction of
needle rotation, from one oE the intermediate yarn feeds
Y'l, Y'2, etc. The air jets Al, A'l, etc., are disposed
adjacent the needle circle at positions proximate to and
trailing locations where the needles reach cast-off level.
Figs. 2 and 3 each illustrate diagrammatically the
outside or backside of two different sliver loop knit
fabrics made on a knitting machine embodying this
invention. Both are jersey knit Eabrics having a
plurality of tufts Tl, T2, T3, T4 of sliver fibers, -the
free ends of which are incorporated into a plurality of
courses and wales, to provide a fabric generally similar
to loop pile fabric. In Figs. 2 and 3, the :Letters a, a',
b, b', c, etc., indicate courses, the letters nl, n2, n3,
n4 indicate neecl:l.e wales and the :Letters sl, s2, s3, s4
indicate sinker wales of the Eabrics. The tufts Tl, T2,
T3, T4 are incorporated into the fabrics both in the form
of knitted stitches and by interlacing. The fabrics have
a loop pile effect on the side comprising the inner
surface of the fabric tube during knitting, and have the
appearance of a jersey knitted web on the opposite side.
The loop pile effect appears on the side oE tile Eabric
which constitutes the pi]e face or pile side of a
conventional single-Eaced sliver knit high pile fabric.
Fig. 2 illustrates a fabric knit on the machine 10
of Fig. 1 by feeding sliver fibers and yarn to the needles
at all the feeding stations Fl, F2, etc., and feeding yarn
to the needles at the intermediate yarn feeds Y'1, Y'2,
etc. For the purpose of illustration only, in relatiny
the fabric illustrated in Fig~ 2 to the machine
illustrated in Fig. 1, the following yarn feeds of the
machine correspond to the following courses of the fabric:
1579-76
Yarn FeedYarn Course
; Yl a .
Y'l ~'
Y2 b
Y'2 b'
:~ Y3 c
Y'3 c'
: Y4 d
Y'4 d'
Y5
etc. etc.
; The correlation between the knit-in sliver tufts
Tl, T2, T3, T4 of the fabric of Fig. 2 and the cards or sliver
; feeding devices of the machine of Fig. 1, for the purpose of
illustration, is as follows:
, , .
.: Fed by Card Sli~Jer Tuft
, . .
. Cl Tl
C2 T2
- C3 T3
C4 T4
.
The sequence of sliver feeding then may be repeated,
as follows:
Fed by Card liver Tuft
C5 Tl
: C6 T2
: C7 T3
C8 T4
. ''' .
. - 13 -
In Fig. 2, each oE the groups or tuEts of plural staple
fibers Tl, T2, T3, T4 are shown as being knit-ted, i.e.
incorporated in the form of knitted stitches, in needle wales
nl, n2 and n3, and are shown traversing sinker wales sl and
s2, with their extreme ends terminating in sinker wale s_.
Successive knitted stitches formed from each o the tufts Tl,
T2, T3, T4 are connected between adjacent courses by diagonal
segments D of sliver fibers. Segments D traverse diagonally
the sinker wales, extending from the base oE one of the
successive stitches to the base of the next following of the
successive stitches. Additionally, a portion P of each tuft Tl,
T2, T3, T4 is illustrated in needle wales nl, n2 as splitting
ofE from the cLiagonal scgments D of thc knitted fibers and
being interlacecl into the cal)r:ic. lhe~ sLiver tut 1`1 is shown
incorporatcd :into lhree SePLlI`ate courses, -viz. a, .l', b.
Similarly, sliver T2 is sllown incorporated into courses b,
b', c; sliver T3 in courses c, c', d; sliver T~ in courses
d, d', e. I~or the purpose of illustra-tion, the several groups
of slivcr fibers Tl, T2, T3, T~l are S}lOWn as having been fed
2Q by thcir respective cards only to the single need:Le forming
needle wale nl. It is to be understood that the same slivers
arc ed to successive needles :Eorming -the successive needle
w.ales n2, n3, n~l, etc., to form course-wise and wale-wise
repeats oE the several Icnit slivers rl`l, T2, T3, T4.
The interlaced portions P are in tlle nature of elongated
floats extcnding across at least two courses and at least
two wales of the fabric. Thus, float P of tuft Tl ex-tends
rom the base of the stitch of Tl fibers knitted in needle
wale nl across sinker wale sl and needle wale n2 to sinke-r
wale s2, where at least some of its fibers, if of sufficient
length, merge into the knitted stitch -formed with fibers of
- 14 -
. ~
tuf~ Tl in course b at needle wale n3. In course a'at needle wale n~, float P of tuft Tl is locked into
the fabric between the base fabric B and the diagonal
seg~en~ D ~ormed of the fibers of tuft Tl. Floats P
of tufts T2, T3 and T4 similarly extend across and
are loc~ed into the fabric. The floats P passing and
trapped between the base fabric B and the diagonal
segments D connecting the stitches Xnitted of the tufts
Tl, T2, T3, T4 tend to raise those seg~ents from the
base fabric to emphasize the loop pile effect. However,
,~
` due to the random disposition or the floats P through-
out the fabric, the floats may be locked into th~
~; fabric, against the base fabric B, by succeeding floats
. .
P as well as by the diagonal segments D. The relatively
short diagonal segments D c~nd the relatively long inte~-
laced floats P constitu~e the loops of fibers providing
the loop pile texture on what normally is the face side of
a conventional sliver knit high pile fabric.
If desired, the fibers o-f selected tufts rnay
have a characteristic differing from the characteristics
of the fibers o the other tufts. For example, the
fibers which compose the pile tufts Tl, 1`2, T3, T4 may
each be of cl diferent or contrasting color, to providc
a multi~colored or multi-]l-led sliver loop knit fabric.
lVhere slivers of different colors are fed to the needles
by the cards Cl, C2, C3, C4, etc., the fabric will in-
corporate a plurality of groups of tufts, with each group
being composed of staple fibers having a color differing
from or contrasting with
- - 15 -
~ 3
1579-76
the colors of the fibers of the other groups of tufts. Of
course, the separate sliver fibers may differ i.n character-
; istics other than or in addition to color, to provide awide range of patterned fa~rics of selected or predetermined
design
The fabric of Fig. 3 differs from that of Fig. 2
only in that the intermediat~ courses a', b', c', etc., are
eliminated. This is accomplished by eliminating or blanking
out the intermediate yarn feeds Y'l, Y'2, Y'3, etc., o the
knltting machine 10 of Fig. 1. For the pllrpose of illustra-
tion only, the correlation between the yarn feeds and cards
of the machine 10 of Fig. 1 and the courses and tufts of
sliver fibers of the fabric of Fig. 3 may be as follows:
Yarn Feed Course
Yl a
Y2 b
~3 c
Y4 d
Y5 e
etc. etc.
Fed by Card Sliver Tuft
Cl Tl
C2 T2
C3 T3
C4 T4
C5 Tl
- C6 T2
C7 T3
C8 T4
As is clearly illustrated by Figs. 2 and 3, re~ar~-
~ess whether the intermediate yarn -feeds Y'l, Y'2, Y'3, etc.,
are utilized, the fabrics of this invention incorporate
sliver fibers in the form o-f knitted s-ti-tches, diagonal seg~
ments D and in-terlaced floats P in all of their courses and
wales.
Referring next to Figs. 4, 5a, 5b, 6, there is
illustrated schematically a modified open top multi-feed
sliver high pile fabric circular knitting machine lO' for
13 knitting the loop knit fabric of Fig. 2 The modified knit
ting machine lO' is identical to the machine lO i].lust:rated
in Fig. 1, except i~ is provided with four feeding stations
rather than eight. Two of the four feeding stations are
indi.cated at F'l, F'2 i.n Fig. 4. ~eeding station F'l includes
the usual wlre-covered rotatable doffer 12 fol feecling staple
sliver fibers to the needles N of the machine lO', and the
usual yarn tube 14 for feeding a yarn a to the needles.
Feeding station F'2 includes rotatable doffer 13 together
with a yarn tube ~not shown).
Disposed intermediate the spaced feeding stations
F'l, F'2 is a second yarn tube 15, for feeding a yarn a' to
the needles N, and a pair of angularly spaced co~pressed air
jets Al', A'l'. The two air jets Al', A'l' are disposed
adjacent the needle circle, with their open ends or orfices
oriented to direct a stream of compressed air in the direction
of the needles. The reciprocable needles N are mounted in
the usual needle cylinder 18 (Fig. 6), and alternate with
the usual reciprocable sinkers S supported by sinker ring 19.
- 17 -
æ~
Fig. 6 illustrates a needle N which previously had
been raised to clear level, and is in the process o:~ receiving
a tu~t T of sliver fibers in its hook. ICnitted ~uft T', fecl
to the needlc N a~ the preceding feeding s~ation, h~ls cleared
the needl~ latch~ Due to the rotation of th~ doffer 12, i-ts
wire clothing brushes the free ends o~ the fibers oE the tu:E-t
: T :inward relative to the needl.e circle, whereby the tu~t
initially is disposed in a more or less U-shaped confuguration
about the needle. The sinkers S are in advanced position
; lO relative to the circle of needles N.
Figs. 5a and 5b show the coordination of the needles
N and the sinkers S during knitting of fabric lntermediate
the anglIlarly spaced dof:~ers 1.2 and 13. As the neecl1.cs N
with the U-shapecI tufts T o:E sliver fibers in their hooks are
rotated past yarn tube 14, they start their descent to cast-
off level, while the sinkers S are retracted from the needle
circle. As the rotating needles descend to cast-ofE level,
they talce yarn a in their hooks. With the upwardly-disp.osed
tufts of fibers T and the yarn a in their hooks, the needles
N reach cast-o~ level, as shown in Fig. 7, and then con~ence
l.o rise to clear level, with the newly formed loops o:E sliver
fibers and yarn still in their hooks. When the need1.es commence
-their ascent -to clear level, the sinkers have been nearly
fully advanced inwardly relative to the needle circle, between
the needles N, to web holding position.
Air jet .Al' is disposed at a location, relative -to
the needle circle, where the needles begin their ascent to
clear level. As the needles ascend, a jet of compressed air
from the nozzle Al' blows the free ends of the tufts T of
fibers outwardly of the needle circle, between the needl.es N, as
illustrated in Fig. 8, onto the tops of the sinkers. This
action of the air jet Al' ultimately causes the free ends of
the tufts of sliver fibers to traverse the sinker wales sl in
the knitted fabric, in the form of diagonal segments D and
interlaced floats P, as illustrated in ~ig. 2. The jet of
compressed air blows not only the tu:Ets o:E :Eibers T under the
needle hooks outwardly of the needle circle, but also blows
; outwardly the free ends o:E the tufts T' anchored by the
cleared stitches below the needle latches ~Figs. 6, 9) and
the tufts anchored by one or more o-E the cast-of-f stitch.es
immediately adjacent the needles, depending on the length
- of the sliver fibers. Tlle result is to mingle the individual
fibers of the several tufts extending outwardly of the needle
circle to form an intermingled mass or web of entangled sliver
fibers in sheet form.
The open end o:E the nozzle Al' is located to direct
a streaTn o.E comprcsscd air generally radially outward o:E the
neeclle ci.rcle. I~or op-timum resul.ts, thc open end o.E the
nozzle Al' may be disposed to direct the stream of compressed
air slightly downward, rather than strictly horizontal, and
slightly rearwardly in the direction of the oncoming rotating
needles N. In such case, the free ends of the tufts o:E
sliver fibers are blown around the needles to extend slightly
diagonally relative to both the si.nkers and the needle
latches, and are held by the compressed air to the tops of
the sinkers at least unt:il the ascending needles have begun
to clear their latches. By directiilg the stream of compressed
air slightly downward, the outwardly e~tending free ends of
the fibers are retained on the tops of the sinkers as the
needles begin to ascend to clear level.
As the needles N rotate past the air jet Al', they
continue their ascent to clear level, preparatory to taking
yarn a' in their hooks. The sinkers S have advanced :Eully
into the needle circle. As the needles ascend, their hooks
- 19 -
~ass through the outwardly extending sheet of fibers, andtheir open and cleared latches engage and retain most of the
~- mingled fibers. The rotating needles N, after clearing,
begin to descend to cast-off level once again, taking the
yarn a' in their hooks, as illustrated in Fig. 9. As the
needles descend to cast-off level, their latches are closed
to trap the portion of the outwardly extending fibers retained
thereon under the needle hooks. The diagollal disl~ositio
o~- the Eibers relative to the ne~dle
latches facilitates this entrapment. The portion o-E the
mingled free ends of the several tufts trilpped under the
nccdle hooks as the needles descend are formed into stitches
with the y~lrn a', whcn the necclles reacll cast-or~ level. ~s
a rcsuLt, -thc tIa~)pc(l ends oE thc tuEts are incorporated into
the fabric, in the form of stitches, in a second course and
a second wale of the Eabric, as illustrated in Fig. 2. This
stitch formation process brings the trapped fiber ends which
had been blown to the outside of the needle circle back to
the inside of the fabric sleeve in the form of knitted
stitchcs to provide the loop pile effect. As the needles
desccnd, -thc:ir closing latches swee~ the sheet oE outwardly
extcnding, diagonal:Ly inclined Eibers, including -the stray
; fibers, upwardly en mass into substantially vertical dis-
position.
The non-trapped or stray fiber ends are interlaced
about the needles, below their latches, by the sinkers. Each
time the sin]<ers S are advanced -to web holding position, they
engage and push the now generally upstanding sheet or mass
of minglcd, diagonally inclined fibers back into the needle
circle. The result of this is to inter:Lace the non-trapped
stray fibers or "tailings" around the needles. As the
- 20 -
:.
sinkers advallce, the forward ends or noses of their nibs
strike the generally upstandillo web of mingled fibers and
commence pushing the fibers en mass inward relative to the
circle of needles. As the sinkers continue to advance, the
upper portions of their front profiles, i.e. their noses,
the under edges of their nibs and their throats, push the
fibers - both those trapped on the needle latches and the
non-trapped stlay fibers below the needle latches - around
the needles into the needle circle as the neeclles ascend to
clear level. Frictional engagement between the sides of the
sinker nibs and the contiguous ~ibers also aids in urging
the fibers into the needlc circlc.
As thc needles N clesccnd to cas-t-o~E :levcl Eor the
second time, the sinkers are retract~d from the needle circle
~or a second time. After the needles N again reach cast-
oEf level, they start their second ascent to clear level, and
the sinkers S again a~vance inwardly of the needle circle.
The air jet A'l' is disposed at a position, relative
- to the needle circle, where the needles begin their next
ascent to clear level. Its open end preferably is
disposed, relative to the needles, in a manner identical
to the disposition of the open end of the nozzle Al'. As
the needles ascend, a jet of compressed air Erom the
nozzle A'l' blows all of the free ends - both trapped ends
and stray ends - of the several tufts of sliver fibers
once again around the needles N and diagonally across the
tops of the sinkers S outwardly of the needle circle, in
; the manner illustrated in Fig. 8. This action oE the air
jet ~'1' ultimately causes the mingled free ends of the
tufts to again traverse the sinker wales in the knitted
fabric, e.g. sinker wales s2 as illustrated in Fig. ~.
- 2l -
..
As the needles N rotate past the air jet A'l', they
continue their ascent to ~l~ar level. In the manner
previously explained, the bulk oE the diagonal, outwardly
extending ~ibers are engayed and retained by the open
latches of the ascendin~ needles. Those fibers are
trapped within the needle hooks when the latches again
close, after the needles have taken fresh sliver fibers
and a new yarn in their hooks and descend to cast-off
level. The trapped fibers are formed into stitches with
the new fibers and yarn, and are incorporated into the
fabric in a third course and a third wale, as illustrated
in Fig. 2
The non-trapped or stray fibers extending outwardly
o~ the needle circle again are pushed by the advancing
sinkers back into the needle circle, against the needles,
below the needle latches in the manner previously explained,
preparatory to being incorporated into the fabric by inter-
lacing. When the needles subsequently descend to cast-off
level for the third time, the non-trapped fibers are cast
over tlle needles alld are incorporated into the fabric in
the form of the interlaccd portions or floats P. The com-
pressed air from the nozzles Al' and A'l' in cooperation
with the inward advances of the sinkers S causes the non-
trapped fiber ends to be intertwined about the needles, and
hence ultima-tely incorporated into the fabric in the form of
the interlocked floats P.
Thus, the non-trapped or stray fibers, referred to
herein as "tailings'l, are manipulated between and about
- the needles in the manner of an interlacement. Initiallyr
the fibers are disposed in generally U-shaped
configuration about the needles, with their free ends
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"
extending inwardly of the needle circle (Figsn 6, 7).Thereupon, their free ends are blown around the needles
and outwardly of the needle circle by the air jets (Fig.
8). Subsequently, the outwardly extending free ends of
the non-trapped fibers, disposed diagonally relative to
the needles as explained above, are urged inwardly to the
needle circle by the advancing sinkers, into contact with
. the needles. When the needles descend to cast-off level,
those fibers are cast over the needles and incorporated
. 10 into the fabric as the interlaced floats P. Next, the
~ree ends of the non-trapped fibers a~ain are blown around
the needles and outwarcl:Ly of the needle circle by the a:ir
jets, fol:Lowing wh.ich they are i.ncorporatecl into the
fabric either in the form of knitted stitches or in the
form of the interlaced floats P.
With the modified knitting machine 10' illustrated
in Figs. 4-6, the needles N.ha~e cleared, and have the bulk
.; o.-f the free ends of the tu.fts T disposed diagonally on their
open latches, as they rotato to the doErer 13, preparatoly
~'
~ .
~ - 23 -
., .
to taking fresh tufts o~ sliver -fibers in their hooks. The
stray ends or "tailings'~ are in~erfaced around the shanks o-f
the needles below their latches. As the needles rotate past
doffer 13, relative to feeding station F'2, they take fresh
tufts oE fibers and then a new yarn in their hooks, Eollow-
ing which they again descend to cast-off level. At such
time, the free ends of the tufts T, trapped in the needle
hooks, are incorporated into the fabric together with the
fresh tufts of sliver fibers and the new yarn.
1~ The needle and sinker cams necessary for the above
described operations of the needles N and sinkers S are a
matter of common and general knowledge in the art. The
selection of the camming to carry out the needle and sinker
knitting manipulations to produce the fabric of Fig. 2 will
be readily apparent to one skilled in the art, and a
detailed description thereof is unnecessary.
Any type of conventional latch knitting needles may be
employed, although it is preferred that needles having
relatively long latches, on the order of .025 to .030 inches
2~ longer in length than normal, be utilized. A needle with a
relatively long latch ensures tha-t the latch will properly
engage and retain the diagonal, outwardly extending fibers,
as the needles ascend to clearing level, preparatory to
trapping the fibers under the needle hooks as previously
explained.
Various patterning effects may be produced in the
` fabric of Fig. 2 by selectively controlling or manipulating
the air jets Al', A'l'. For example, the quantity, pressure
or degree of compressed air emitted from the air jets may be
- 2~ -
selectively controlled, by selectively varying the size of
the orifices of the air nozzles or by means of valves V o-f
the type illustrated in Fig. 1, to produce various rib,
corduroy, loop pile, etc. pattern effects. Variations in air
volume and pressure at each air jet or nozzle, or continuous
or intermittent air flow, may be controlled selectively by a
programmed solenoid valve system. Additionally, the location
or positioning of the open ends or orifices of the air jets
Al', A'l' may be selectively varied relative to the sinkers,
the needles, the cast-off positions of the needles, etc.,
thereby varying loop size to produce a variety of fabric
patterning. The open ends of the air jets are disposed so
as to direct the streams of compressed air generally radially
outward of the needle circle. However, positioning the open
ends of the air jets to clirect thelr air streams slightly
downwardly, and slightly rcarwardly in the dircctlon ol the
oncoming needles, helps ensure that the bulk o-f the outwardly
extending fibers of each tuft T will be blown to one side of
the needle on which they are retained, thus ensuring that the
bulk of such fibers will traverse the sinker wales in the
manner illustrated in Figs. 2 and 3. Selective positioning,
control or adjustments of the air jets permit variations in
the size of the pile loops of the sliver fibers constituting
the tufts T, as the free ends o the tufts are blown outwardly
relatlve to the needle circle during knitting.
In the practice of this invention, a suction hood
(not shown) is disposed ~ithin the needle circle, to control
fly loss of sliver fibers during the knitting. In the practice
~ of this invention, for the purpose of controlling fly loss,
; 30 and to improve the quality of the sliver loop knit fabrics
made possible by the in~cntion, the suction hood may be pro-
vided with radial extensions for overlying at least a portion
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-76
of the cards delivering sliver fibers to the needles, Pre
ferably, such radial extensions of the hood e~tend suffi-
ciently far in the direction of the cards to cover or
shield completely the doffers of each card.
Figs. lOa and lOb are views similar to Figs. 5a
and Sb, illustrating the arrangement for knitting the loop
knit fabric of Fig. 3. In the arrangement of Figs. lOa,
lOb, the second yarn tube 15 and the second air jet A'l'
- are eliminated. In the arcuate space between the feeding
~) stations F'l and F'2, there is disposed a single yarn tube
14, feeding a yarn a to the needles ~, and a single air jet
~l'. In Fig lOa, jet Al' is spaced somewhat further, in
the direction of needle rotation, from the location on the
needle circle where the needles descend to cast-off level
i than in Fi.g. Sa. ~s will be understood by those skilled in
the art, the elimination of the inter~ediate yarn tubes and
yarns, such as ~arn tube 15 and yarn a', from the knittlng
arrangement shown in Figs. lOa, lOb, eliminates the alternate
yarn courses a', b', c', etc., from the fabric of Fig. 3.
The number of different courses and wales in which
the staple fibers constitutin~ the tufts T are incorporated
in a sliver loop knit fabric of this invention may depend
on the length of the discrete fibers forming the slivers.
The greater the staple length of the sliver fibers, the
i greater the number of fabric courses and wales into which the
fibers can be incorporated. For example, if relatively short
sliver fibers are utilized for the Icnitting of the fabric
of Fig. 3, the fibers constituting the tufts Tl, T2, T3, T4
may be incorporated only in two courses and two ~ales of the
- 26 -
fabric. If relatively long sliver fiber is utili~ed, the free
ends of the tufts may be incorporated into three, four or more
different courses and wales of the fabric.
As the needles rotate relative to the sliver and yarn
feeding stations, passing successive air jets, the free ends
of the tufts are repeatedly blown outwardly of the needle
circle, until such free ends have been fully incorporated by
knitting and interlacing into the fabric. The advance of the
sinkers into the needle circle, each time the needles ascend
from succeedi.ng cast-off locations spaced around the needle
circl~, will continue to interlace the free ends of any stray-
fibers o~ ~he tufts about the needles, until all such fi~ers
have been fully incorporated into the fabric. As will be
understood, the selection of the ].englh of sliver fibers
' utilized i.s a matter of c'holce, to 'be chosen according to
the particular fabric pattern effect deslred. Preferably,
the bulk of the free ends of the sliver fibers are incorporated
into the fabrlc in the orm of knitted stit'ches, rather than
by interlaclng. The ratlo quantlty of fibers knit into the
fabric, in comparison to those interlaced therein, is determined
- by the length of the latches of the needles N. The longer the
latches, and the closer they extend, when open, to the tops of
the sinkers, as illustrai.ed in Fig 9, the greater will be the
quantity of Eibers retained by the open latches and trapped
withln the needle hooks, when the latches close, preparatory
to forming the fibers into knitted stitches in -the fabric.
Although preferred embodiments of this invention have
been shown and described for the purpose of illustration, as
required by Title 35 U.S.C. 112, it is to be understood that
various changes and modifications may be made therein without
departing from the spirit and utility of the invention, or
the scope thereof as set forth in the appended cla:ims.
- 27 -
