High seed yarn knitting apparatus

Abstract

A knitting machine is described in which the elastic thread packages ( 26 ) are mounted in a stationary position away from the knitting head ( 22 ). This results in reducing the revolving mass and the space necessary to accommodate the revolving mass. Furthermore, the commencement of wind on the package ( 26 ) can be left as a tail which is knotted to the free end of a second package thus permitting the machine to run continuously without stopping to change packages. A plurality of like knitting heads ( 22 ) is mounted in relatively close proximity in a single knitting head frame ( 24 ) in such a manner that chain stitches are fed from a power driven warp beam ( 12, 16, 20 ). Each knitting head includes yarn positioning apparatus in which yarn ( 12 ) fed to each needle ( 30 ) of the knitting head ( 22 ) is moved under tension with minimal friction to a position where the needle ( 30 ) traps the yarn ( 12 ) on its downward stroke. Embodiments of the invention are described.

I claim:  
     
       1. A knitting head for use with a knitting machine, said knitting head comprising: a fixed hollow cylinder wall having an inside and an outside and with a plurality of circumferentially spaced grooves disposed in said wall, each groove having a needle with a hook at an upper end disposed therein, said hollow cylinder being disposed in a cam box having rotary cam means coupled to each needle so that rotation of said rotary cam means causes displacement of each needle along its respective groove, stationary warp yarn delivery means disposed above said hollow cylinder for feeding a warp yarn from a remote location to each respective needle for being knitted into a warp chain, rotatable weft yarn delivery means disposed between said hollow cylinder and said stationary warp yarn delivery means and including a weft yarn guide extending from the inside of the cylinder wall to the outside of the wall for delivering a weft yarn from the inside to the outside of said cylinder wall to lay the weft yarn externally of each needle so that the weft yarn is trapped by the knitted warp chains without being knit itself, said rotary cam means and said rotatable weft yarn delivery means being rotated in synchronization whereby, in use, upon rotation of said rotary cam means and said rotatable weft yarn delivery means displacement of said needles causes chain stitches to be made which are fed inside said cylinder, and said rotatable weft yarn delivery means delivers said weft yarn outside said needles as said needles rise and the tension in said weft yarn pulls the weft yarn over the top of the needle when the needle descends to trap the weft yarn in a subsequent stitch which falls behind the needle as the stitch is made. 
     
     
       2. A knitting head as claimed in  claim 1  wherein each said needle includes a pivotable latch for preventing said weft yarn from being hooked by said needle on a downward stroke. 
     
     
       3. A knitting head as claimed in  claim 1  wherein said stationary warp yarn delivery means comprises a plurality of stationary warp yarn delivery elements, a respective element being associated with a respective needle and being vertically disposed above said needle but being slightly offset therefrom to permit said needle to lie vertically above said element to collect a length of thread as it descends. 
     
     
       4. A knitting head as claimed in  claim 3  wherein said element is in the form of a generally horizontal bar having an aperture therein through which said warp yarn is passed. 
     
     
       5. A knitting head as claimed in  claim 4 for use with a knitting machine, said knitting head comprising: 
       
         a fixed hollow cylinder wall having an inside and an outside and with a plurality of circumferentially spaced grooves disposed in said wall, each groove having a needle with a hook at an upper end disposed therein,  
       
       
         said hollow cylinder being disposed in a cam box having rotary cam means coupled to each needle so that rotation of said rotary cam means causes displacement of each needle along its respective groove,  
       
       
         stationary warp yarn delivery means disposed above said hollow cylinder for feeding a warp yarn from a remote location to each respective needle for being knitted into a warp chain,  
       
       
         rotatable weft yarn delivery means disposed between said hollow cylinder and said stationary warp yarn delivery means and including a weft yarn guide extending from the inside of the cylinder wall to the outside of the wall for delivering a weft yarn from the inside to the outside of said cylinder wall to lay the weft yarn externally of each needle so that the weft yarn is trapped by the knitted warp chains without being knit itself, said rotary cam means and said rotatable weft yarn delivery means being rotated in synchronization whereby, in use, upon rotation of said rotary cam means and said rotatable weft yarn delivery means displacement of said needles causes chain stitches to be made which are fed inside said cylinder, and said rotatable weft yarn delivery means delivers said weft yarn outside said needles as said needles rise and the tension in said weft yarn pulls the weft yarn over the top of the needle when the needle descends to trap the weft yarn in a subsequent stitch which falls behind the needle as the stitch is made,  
       
       
         wherein said stationary warp yarn delivery means comprises a plurality of stationary warp yarn delivery elements, a respective element being associated with a respective needle and being vertically disposed above said needle but being slightly offset therefrom to permit said needle to lie vertically above said element to collect a length of thread as it descends, and  
       
       
         wherein said element is in the form of a generally horizontal bar having an aperture therein through which said warp yarn is passed, and  
       
       wherein each element includes a latch stop for restricting the upward pivotable movement of each latch on said needle.  
     
     
       6. A knitting head as claimed in  claim 1 for use with a knitting machine, said knitting head comprising: 
       
         a fixed hollow cylinder wall having an inside and an outside and with a plurality of circumferentially spaced grooves disposed in said wall, each groove having a needle with a hook at an upper end disposed therein,  
       
       
         said hollow cylinder being disposed in a cam box having rotary cam means coupled to each needle so that rotation of said rotary cam means causes displacement of each needle along its respective groove,  
       
       
         stationary warp yarn delivery means disposed above said hollow cylinder for feeding a warp yarn from a remote location to each respective needle for being knitted into a warp chain,  
       
       
         rotatable weft yarn delivery means disposed between said hollow cylinder and said stationary warp yarn delivery means and including a weft yarn guide extending from the inside of the cylinder wall to the outside of the wall for delivering a weft yarn from the inside to the outside of said cylinder wall to lay the weft yarn externally of each needle so that the weft yarn is trapped by the knitted warp chains without being knit itself, said rotary cam means and said rotatable weft yarn delivery means being rotated in synchronization whereby, in use, upon rotation of said rotary cam means and said rotatable weft yarn delivery means displacement of said needles causes chain stitches to be made which are fed inside said cylinder, and said rotatable weft yarn delivery means delivers said weft yarn outside said needles as said needles rise and the tension in said weft yarn pulls the weft yarn over the top of the needle when the needle descends to trap the weft yarn in a subsequent stitch which falls behind the needle as the stitch is made, and  
       
       wherein said rotatable weft yarn delivery means comprises a generally planar horizontal weft yarn rotatable feeder and deflector element, said rotatable feeder and deflector element being coupled to a rotatable hollow yarn delivery tube driven by drive means, said tube and said rotating feeder and deflector having passage means through which a weft thread can be fed to be disposed outside the periphery of the hollow cylinder.  
     
     
       7. A knitting head as claimed in  claim 6  wherein the deflector includes an outer cam portion for deflecting the warp yarn outside the periphery of the hollow cylinder as said deflector rotates. 
     
     
       8. A knitting head as claimed in  claim 6  wherein said tubular yarn delivery tube is rotatable via bearing means in a support tube fixed and coupled to said stationary warp delivery means. 
     
     
       9. A knitting machine comprising: 
       warp yarn delivery means for delivering a plurality of warp yarns to at least one knitting head, said knitting head being disposed in a knitting head frame and the knitting head receiving a plurality of warp yarns for knitting the warp yarns into distinct warp chains without being knit itself, and having rotating weft yarn delivery means substantially disposed within the knitting head for delivering a weft yarn to be trapped by the knitted warp chains, said knitting head frame having a plurality of stationary weft yarn package holders disposed at a remote position from said knitting head and frame and for supplying said at least one knitting head with weft yarn, and fabric take-off roll disposed in said knitting head frame for receiving knitted fabric from said knitting machine.  
     
     
       10. A knitting machine as claimed in  claim 9  wherein said knitting machine has a plurality of knitting heads and said warp is driven by warp drive rollers and said warp yarn is fed across to said knitting head frame via a warp sheet. 
     
     
       11. A knitting machine as claimed in  claim 9 or  claim 10   wherein yarn tensioning devices are provided from  for controlling the tension of each yarn fed to respective knitting heads. 
     
     
       12. A knitting machine as claimed in  claim 9  wherein said knitting machine has a single head and said warp yarn is fed to said single head from a creel having a plurality of package holders. 
     
     
       13. A method of knitting a tubular fabric comprising the steps of: 
       feeding a plurality of warp yarn threads to a knitting head including vertically moveable needles so as to knit the warp yarn threads into chains, said knitting head including an inside and an outside, feeding at least one weft yarn inside said knitting head from a remote location outside the knitting head; delivering the weft yarn from the inside to the outside of said knitting head so that the weft yarn is trapped by the knitted warp chains without being knit, and disposing said weft yarn initially on the outside of said knitting head by a rotary movement of an outer cam portion of a deflector element to lay the weft yarn outside said needles as the needles rise, synchronizing movement and displacement of needles with respect to the delivery of the weft yarn to cause the weft yarn disposed around the outside of said knitting head to be trapped between successive stitches of said warp yarn and to fall behind the needle as a stitch is made to create a tubular structure.  
     
     
       14. A method as claimed in  claim 13  wherein said method includes the step of feeding said warp yarn threads and said at least one weft yarn from a remote stationary location. 
     
     
       15. A method as claimed in  claim 13  or  claim 14  wherein said warp yarns are fed vertically downwards to vertically disposed knitting heads. 
     
     
       16. A method as claimed in  claim 13  wherein the delivery of the weft yarn and the movement and displacement of the needles in the knitting head is synchronized. 
     
     
       17. A method as claimed in  claim 13  wherein the remote location comprises two stationary package holders for each knitting head and yarn packages held on the package holders are tied together to provide substantially continuous knitting by each knitting head to produce a continuous tubular fabric. 
     
     
       18. A knitting head as claimed in  claim 1 , further including  for use with a knitting machine, said knitting head comprising: 
       
         a fixed hollow cylinder wall having an inside and an outside and with a plurality of circumferentially spaced grooves disposed in said wall, each groove having a needle with a hook at an upper end disposed therein,  
       
       
         said hollow cylinder being disposed in a cam box having rotary cam means coupled to each needle so that rotation of said rotary cam means causes displacement of each needle along its respective groove,  
       
       
         stationary warp yarn delivery means disposed above said hollow cylinder for feeding a warp yarn from a remote location to each respective needle for being knitted into a warp chain,  
       
       
         rotatable weft yarn delivery means disposed between said hollow cylinder and said stationary warp yarn delivery means and including a weft yarn guide extending from the inside of the cylinder wall to the outside of the wall for delivering a weft yarn from the inside to the outside of said cylinder wall to lay the weft yarn externally of each needle so that the weft yarn is trapped by the knitted warp chains without being knit itself, said rotary cam means and said rotatable weft yarn delivery means being rotated in synchronization whereby, in use, upon rotation of said rotary cam means and said rotatable weft yarn delivery means displacement of said needles causes chain stitches to be made which are fed inside said cylinder, and said rotatable weft yarn delivery means delivers said weft yarn outside said needles as said needles rise and the tension in said weft yarn pulls the weft yarn over the top of the needle when the needle descends to trap the weft yarn in a subsequent stitch which falls behind the needle as the stitch is made, and  
       
       a warp yarn positioning apparatus used in a high speed knitting apparatus, comprising a knitting head having a plurality of needles, each of said needles being movable in a needle trick, said warp yarn positioning apparatus comprising a plurality of warp yarn guides, each guide defining an aperture for receiving a respective warp yarn passing therethrough and for containing and controlling movement of each of said warp yarns, each warp yarn guide being mounted above a respective needle, at least one yarn deflecting means for rotating  being adapted to rotate around said knitting head for engaging said warp yarns and for deflecting said yarns across said aperture from a first position to a second position such that, in said second position, each of said yarns is trapped by a  its respective needle as the needle  it descends.  
     
     
       19. Yarn positioning apparatus as claimed in  claim 18 , wherein each yarn guide is a hardened wire staple. 
     
     
       20. Yarn positioning apparatus as claimed in  claim 18  or  claim 19  wherein each of said yarn guides are mounted in a plane on a shallow cylindrical stationary dial, said dial being disposed above said knitting head. 
     
     
       21. Yarn positioning apparatus as claimed in  claim 18  wherein said yarn deflecting means is a planar placing element, said planar placing element being movable around said knitting head and passing above each of said apertures. 
     
     
       22. Yarn positioning apparatus as claimed in  claim 21  wherein a plurality of placing elements are mounted on an elongate member connected to a cam box, said placing elements being associated with a cam of said cam box and said cam box being rotatable around said stationary dial. 
     
     
       23. Yarn positioning apparatus as claimed in  claim 18 , wherein said yarn deflecting means is by a planar placing element, said placing element being movable around said knitting head and passing beneath the yarn guides. 
     
     
       24. A knitting head for use with a knitting machine, said knitting head comprising: a fixed hollow cylinder wall having an inside and an outside and with a plurality of circumferentially spaced grooves disposed in said wall, each groove having a needle with a hook at an upper end disposed therein, said hollow cylinder being disposed in a cam box having a rotary cam means coupled to each needle so that rotation of said rotary cam means causes displacement of each needle along its respective groove, stationary warp yarn delivery means disposed above said hollow cylinder for feeding a warp yarn from a remote location to each respective needle, rotatable weft yarn delivery means disposed between said hollow cylinder and said stationary warp yarn delivery means and including a weft yarn guide extending from the inside of the cylinder wall to the outside of the wall for delivering a weft yarn from the inside to the outside of said cylinder wall to lay the weft yarn externally of each needle, said rotary cam means and said rotatable weft yarn delivery means being rotated in synchronization whereby, in use, upon rotation of said rotary cam means and said rotatable weft yarn delivery means displacement of said needles causes chain stitches to be made which are fed inside said cylinder, and said rotatable weft yarn delivery means delivers said weft yarn outside said needles as said needles rise and the tension in said weft yarn pulls the weft yarn over the top of the needle when the needle descends to trap the weft yarn in a subsequent stitch which falls behind the needle as the stitch is made, said rotatable weft yarn delivery means comprising a generally planar horizontal weft yarn rotatable feeder and deflector element, said rotatable feeder and deflector element being coupled to a rotatable hollow yarn delivery tube driven by drive means, said tube and said rotating feeder and deflector having passage means through which a weft thread can be fed to be disposed outside the periphery of the hollow cylinder, the deflector including an outer cam portion for deflecting the warp yarn outside the periphery of the hollow cylinder as said deflector rotates. 
     
     
       25. A knitting head as claimed in  claim 24  wherein each said needle includes a pivotable latch for preventing said weft yarn from being hooked by said needle on a downward stroke. 
     
     
       26. A knitting head as claimed in  claim 24  wherein said stationary warp yarn delivery means comprises a plurality of stationary warp yarn delivery elements, a respective element being associated with a respective needle and being vertically disposed above said needle but being slightly offset therefrom to permit said needle to lie vertically above said element to collect a length of thread as it descends. 
     
     
       27. A knitting head as claimed in  claim 26  wherein said element is in the form of a generally horizontal bar having an aperture therein through which said warp yarn is passed. 
     
     
       28. A knitting head as claimed in  claim 27  wherein each element includes a latch stop for restricting the upward pivotable movement of each latch on said needle. 
     
     
       29. A knitting head as claimed in  claim 24  wherein said rotatable weft yarn delivery means comprises a generally planar horizontal weft yarn rotatable feeder and deflector element, said rotatable feeder and deflector element being coupled to a rotatable hollow yarn delivery tube driven by drive means, said tube and said rotating feeder and deflector having passage means through which a weft thread can be fed to be disposed outside the periphery of the hollow cylinder. 
     
     
       30. A knitting head as claimed in  claim 29  wherein the deflector includes an outer cam portion for deflecting the warp yarn outside the periphery of the hollow cylinder as said deflector rotates. 
     
     
       31. A knitting head as claimed in  claim 24  wherein said tubular yarn delivery tube is rotatable via bearing means in a support tube fixed and coupled to said stationary warp delivery means. 
     
     
       32. A knitting machine comprising: warp yarn delivery means for delivery a plurality of warp yarns to at least one knitting head, said knitting head being disposed in a knitting head frame and the knitting head receiving a plurality of warp yarns and having rotating weft yarn delivery means substantially disposed within the knitting head, said knitting head frame having a plurality of stationary weft yarn package holders disposed at a remote position from said knitting head and frame and for supplying said at least one knitting head with weft yarn, and fabric take- off roll disposed in said knitting head frame for receiving knitted fabric from said knitting machine, said rotating weft yarn delivery means comprising a generally planar horizontal weft yarn rotatable feeder and deflector element, said rotatable feeder and deflector element being coupled to a rotatable hollow yarn delivery tube driven by drive means, said tube and said rotating feeder and deflector element having passage means through which a weft thread can be fed to be disposed outside the knitting head, the deflector element including an outer cam portion for deflecting the warp yarn outside the periphery of the knitting head as said deflector element rotates.   
     
     
       33. A knitting machine as claimed in  claim 32  wherein said knitting machine has a plurality of knitting heads and said warp is driven by warp drive rollers and said warp yarn is fed across to said knitting head frame via a warp sheet. 
     
     
       34. A knitting machine as claimed in  claim 32  or  claim 33  wherein yarn tensioning devices are provided from controlling the tension of each yarn fed to respective knitting heads. 
     
     
       35. A knitting machine as claimed in  claim 32  wherein said knitting machine has a single head an said warp yarn is fed to said single head from a creel having a plurality of package holders. 
     
     
       36. A method of knitting a tubular fabric comprising the steps of: feeding a plurality of warp yarns threads to a knitting head including vertically moveable needles, said knitting head including an inside and an outside, feeding at least one weft yarn inside said knitting head from a remote location outside the knitting head; delivering the weft yarn from the inside to the outside of said knitting head by a rotatable weft yarn delivery means comprising a generally planar horizontal weft yarn rotatable feeder and deflector element, said rotatable feeder and deflector element being coupled to a rotatable hollow yarn delivery tube driven by drive means, said tube and said rotating feeder and deflector element having passage means through which a weft thread is fed and disposing said weft yarn initially on the outside of said knitting head by a rotary movement of an outer cam portion of said deflector element to lay the weft yarn outside said needles as the needles rise, synchronizing movement and displacement of needles with respect to the delivery of the weft yarn to cause the weft yarn disposed around the outside of said knitting head to be trapped between successive stitches of said warp yarn and to fall behind the needle as a stitch is made to create a tubular structure. 
     
     
       37. A method as claimed in  claim 36  wherein said method includes the step of feeding said warp yarn threads and said at least one weft yarn from a remote stationary location. 
     
     
       38. A method as claimed in  claim 36  or  claim 37  wherein said warp yarns are fed vertically downwards to vertically disposed knitting heads. 
     
     
       39. A method as claimed in  claim 36  wherein the delivery of the weft yarn and the movement and displacement of the needles in the knitting head is synchronized. 
     
     
       40. A method as claimed in  claim 36  wherein the remote location comprises two stationary package holders for each knitting head and yarn packages held on the package holders are tied together to provide substantially continuous knitting by each knitting head to produce a continuous tubular fabric. 
     
     
       41. A knitting machine comprising: warp yarn delivery means for delivering a plurality of warp yarns to at least one knitting head, said knitting head being disposed in a knitting head frame and the knitting head receiving a plurality of warp yarns for knitting the warp yarns into distinct warp chains without being knit itself, and having rotating weft yarn delivery means substantially disposed within the knitting head for delivery a weft yarn to be trapped by the knitted warp chains, said knitting head frame having a plurality of stationary weft yarn package holders disposed at a remote position from said knitting head and frame and for supplying said at least one knitting head with weft yarn, and fabric take- off roll disposed in said knitting head frame for receiving knitted fabric from said knitting machine, wherein said knitting machine has a plurality of knitting heads and said warp is driven by warp drive rollers and said warp yarn is fed across to said knitting head frame via a warp sheet, and wherein yarn tensioning devices are provided for controlling the tension of each yarn fed to respective knitting heads.   
     
     
       42. A method of knitting a tubular fabric comprising the steps of: feeding a plurality of warp yarn threads to a knitting head including vertically moveable needles so as to knit the warp yarn threads into chains, said knitting head including an inside and an outside, feeding at least one weft yarn inside said knitting head from a remote location outside the knitting head; delivering the weft yarn from the inside to the outside of said knitting head so that the weft yarn is trapped by the knitted warp chains without being knit, and disposing said weft yarn initially on the outside of said knitting head by a rotary movement to lay the weft yarn outside said needles as the needles rise, synchronizing movement and displacement of needles with respect to the delivery to the weft yarn to cause the weft yarn disposed around the outside of said knitting head to be trapped between successive stitches of said warp yarn and to fall behind the needle as a stitch is made to create a tubular structure.