Warp knitted fabric and method of manufacturing the same

Abstract

A warp knitted fabric includes a set of non-elastomeric yarn of substantially the same type, fully threaded from a guide bar at the front side of the Tricot type warp knitting machine and knitted in a close 2×1 stitch pattern, and a set of elastomeric yarn of substantially the same type, fully threaded from a guide bar at the rear side of the Tricot type warp knitting machine and knitted in an open 1×1 pillar stitch pattern. The gripping and gummy characteristics on the technical face of the fabric composed of the non-elastomeric and elastomeric yarns are firmly accomplished and quantifiably exposed. A method of manufacturing the warp knitted fabric of this type is also disclosed.

What is claimed is: 
     
         1 . A warp knitted fabric comprising:
 (a) a set of non-elastomeric yarns of substantially the same type, fully threaded from a first guide bar at a front side of a Tricot type warp knitting machine and knitted in a close 2×1 stitch pattern with the formulated effective ranges of:
 I. yarn runner length, in the unit of millimeter per rack; and 
 II. aggregate linear mass density of yarn(s), in the unit of denier, in accordance with a gauge of the knitting machine being adopted; and 
   (b) a set of elastomeric yarns of substantially the same type, fully threaded from a second guide bar at a rear side of the Tricot type warp knitting machine and knitted in an open 1×1 pillar stitch pattern with formulated effective ranges of:
 I. yarn runner length, in the unit of millimeter per rack; and 
 II. aggregate linear mass density of yarn(s), in the unit of denier, in accordance with the gauge of the knitting machine being adopted; 
   (c) wherein the gripping and gummy characteristics on a technical face of the knitted fabric comprised of the non-elastomeric and elastomeric yarns are firmly accomplished and quantifiably uncovered.   
     
     
         2 . The fabric as claimed in  claim 1 , wherein the formulated effective ranges of the yarn runner length, in the unit of millimeter per rack, of the non-elastomeric yarn against the machine gauge, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine are:
 (a) the yarn runner length at a high side boundary that equal 4213×e −0.0344×(machine gauge)  with rounded off decimal; wherein “e” equals a constant number of “2.718281828459045 . . . ”; and   (b) the yarn runner length at a low side boundary that equals 3447×e −0.0344×(machine gauge)  with rounded off decimal; and   (c) the ranges of the effective yarn runner length between the numerical solutions, with rounded off decimal, at the high side boundary in  2 (a) and the low side boundary in  2 (b).   
     
     
         3 . The fabric as claimed in  claim 1 , wherein the formulated effective ranges of the yarn runner length, in the unit of millimeter per rack, of the elastomeric yarn, wrapped on the warp beam(s) with 50% accumulated beaming stretch, against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine are:
 (a) the yarn runner length at a high side boundary that equals 3246×e −0.0456×(machine gauge)  with rounded off decimal; and   (b) the yarn runner length at a low side boundary that equals 2399×e −0.0456×(machine gauge)  with rounded off decimal; and   (c) the ranges of the effective yarn runner lengths between the numerical solutions, with rounded off decimal, at the high side boundary in  3 (a) and the low side boundary in  3 (b).   
     
     
         4 . The fabric as claimed in  claim 1 , wherein the formulated effective ranges of the aggregate linear mass density, in the unit of denier, of the non-elastomeric yarn(s) against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine are:
 (a) the aggregate linear mass density at a high side boundary that equals 1398×e −0.1×(machine gauge)  with rounded off decimal; and   (b) the aggregate linear mass density at a low side boundary that equals 466×e −0.1×(machine gauge)  with rounded off decimal; and   (c) the ranges of the effective linear mass densities between the numerical solutions, with rounded off decimal, at the high side boundary in  4 (a) and the low side boundary in  4 (b).   
     
     
         5 . The fabric as claimed in  claim 1 , wherein the formulated effective ranges of the aggregate linear mass density, in the unit of denier, of the elastomeric yarn(s) against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine are:
 (a) the aggregate linear mass density at a high side boundary that equals 1463×e −0.0832×(machine gauge)  with rounded off decimal; and   (b) the aggregate linear mass density at a low side boundary that equals 488×e −0.0832×(machine gauge)  with rounded off decimal; and   (c) the ranges of the effective linear mass densities between the numerical solutions, with rounded off decimal, at the high side boundary in  5 (a) and the low side boundary in  5 (b).   
     
     
         6 . The fabric as claimed in  claim 1 , wherein the threading of the non-elastomeric yarns is full threading. 
     
     
         7 . The fabric as claimed in  claim 1 , wherein the threading of the elastomeric yarns is full threading. 
     
     
         8 . The fabric as claimed in  claim 1 , wherein the non-elastomeric yarns are nylon yarns. 
     
     
         9 . The fabric as claimed in  claim 1 , wherein the elastomeric yarns are spandex yarns. 
     
     
         10 . A method of manufacturing warp knitted fabrics comprising the steps of:
 (a) selecting a machine gauge of a Tricot type warp knitting machine based on a required fabric weight in the unit of gram per square meter; and   (b) selecting an aggregate linear mass density of a non-elastomeric yarn with first formulated effective ranges for an applicable yarn fineness, corresponding to the gauge of the warp knitting machine being adopted; and   (c) selecting an aggregate linear mass density of an elastomeric yarn with second formulated effective ranges for an applicable yarn fineness, corresponding to the gauge of the warp knitting machine being adopted; and   (d) selecting a runner length of the non-elastomeric yarn with first formulated effective ranges for an applicable yarn runner length, corresponding to the gauge of the warp knitting machine being adopted; and   (e) selecting a runner length of the elastomeric yarn with second formulated effective ranges for an applicable yarn runner length, corresponding to the gauge of the warp knitting machine being adopted; and   (f) knitting a set of the non-elastomeric yarns of substantially the same type, fully threaded from a first guide bar at a front side of the Tricot type warp knitting machine and knitted in a close 2×1 stitch pattern; and   (g) knitting a set of the elastomeric yarns of substantially the same type, fully threaded from a second guide bar at a rear side of the Tricot type warp knitting machine and knitted in an open 1×1 pillar stitch pattern;   (h) wherein the gripping and gummy characteristics on a technical face of the knitted fabric comprised of the non-elastomeric and elastomeric yarns are firmly accomplished and quantifiably uncovered.   
     
     
         11 . The method as claimed in  claim 10 , wherein major processes of manufacturing the warp knitted fabrics comprise the techniques of:
 (a) establishing the first formulated effective ranges of the aggregate linear mass density, in the unit of denier, of the non-elastomeric yarn(s) against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine where:
 I. the aggregate linear mass density at a high side boundary equals 1398×e −0.1×(machine gauge)  with rounded off decimal; and 
 II. the aggregate linear mass density at a low side boundary equals 466×e −0.1×(machine gauge)  with rounded off decimal; and 
 III. the ranges of the effective linear mass densities are laid between the numerical solutions, with rounded off decimal, at the high side boundary in  11 (a)I and the low side boundary in  11 (a)II; and 
   (b) establishing the second formulated effective ranges of the aggregate linear mass density, in the unit of denier, of the elastomeric yarn(s) against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, of the Tricot type warp knitting machine where:   I. the aggregate linear mass density at a high side boundary equals 1463×e −0.0832×(machine gauge)  with rounded off decimal; and   II. the aggregate linear mass density at a low side boundary equals 488×e −0.0832×(machine gauge)  with rounded off decimal; and   III. the ranges of the effective linear mass densities are laid between the numerical solutions, with rounded off decimal, at the high side boundary in  11 (b)I and the low side boundary in  11 (b)II.   
     
     
         12 . The method as claimed in  claim 10 , wherein major processes of manufacturing the warp knitted fabrics comprise the techniques of:
 (a) establishing the first formulated effective ranges of the runner length, in the unit of millimeter per rack, of the non-elastomeric yarn(s), fully threaded from a guide bar at the front side of the Tricot type warp knitting machine, against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, where:
 I. the yarn runner length at a high side boundary equals 4213×e −0.0344×(machine gauge)  with rounded off decimal; and 
 II. the yarn runner length at a low side boundary equals 3447×e −0.0344×(machine gauge)  with rounded off decimal; and 
   III. the ranges of the effective yarn runner lengths are laid between the numerical solutions, with rounded off decimal, at the high side boundary in  12 (a)I and the low side boundary in  12 (a)II; and   (b) establishing the second formulated effective ranges of the runner length, in the unit of millimeter per rack, of the elastomeric yarn, wrapped on the warp beam(s) with 50% accumulated beaming stretch and fully threaded from a guide bar at the rear side of the Tricot type warp knitting machine, against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, where:
 I. the yarn runner length at a high side boundary equals 3246×e −0.0456×(machine gauge)  with rounded off decimal; and: 
 II. the yarn runner length at a low side boundary equals 2399×e −0.0456×(machine gauge)  with rounded off decimal; and 
 III. the ranges of the effective yarn runner lengths are laid between the numerical solutions, with rounded off decimal, at the high side boundary in  12 (b)I and the numerical solution at the low side boundary in  12 (b)II. 
   
     
     
         13 . The method as claimed in  claim 10 , wherein major processes of manufacturing the warp knitted fabrics comprise the techniques of:
 (a) establishing effective ranges of fabric pulling tension immediately after the fabric being formed on the Tricot type warp knitting machine, also known as take-up tension, in the unit of course per centimeter, against the machine gauges, ranged inclusively from 28 needles per inch through 50 needles per inch, where:
 I. the take-up tension at a high side boundary equals the numerical solution, with rounded off decimal, of the product of the positive rational number of “1.15” and the positive integer number of the machine gauge being adopted, added by the positive integer number of “16”; and 
 II. the take-up tension at a low side boundary equals the numerical solution, with rounded off decimal, of the product of the positive rational number of “0.85” and the positive integer number of the machine gauge being adopted, added by the positive integer number of “12”; and 
 III. the ranges of the effective take-up tensions are laid between the numerical solutions, with rounded off decimal, at the high side boundary in  13 (a)I and the low side boundary in  13 (a)II. 
   
     
     
         14 . The method as claimed in  claim 10 , wherein the knitting of the non-elastomeric and elastomeric yarns is carried out by a Tricot type warp knitting machine. 
     
     
         15 . The method as claimed in  claim 10 , wherein the non-elastomeric yarns are nylon yarns. 
     
     
         16 . The method as claimed in  claim 10 , wherein the elastomeric yarns are spandex yarns. 
     
     
         17 . An article of clothing made of the warp knitted fabric as claimed in  claim 1 .