US20220119995A1

US20220119995A1 - Knitting machine and knitting method

Info

Publication number: US20220119995A1
Application number: US17/418,329
Authority: US
Inventors: Yuichi Hirose
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-12-28
Filing date: 2019-12-27
Publication date: 2022-04-21
Also published as: WO2020136915A1; JPWO2020138415A1; JP7103557B2; WO2020138415A1

Abstract

A knitting mechanism 7 of a knitting machine 1 knits a knitted product by overlaying a knitted fabric in a plurality of layers. When knitting the knitted product, the knitting mechanism 7 retains a loop formed when knitting an (N−1)th-layer knitted fabric (N being an integer of 2 or more) even after completion of the knitting the (N−1)th-layer knitted fabric, and when knitting stitches in an Nth-layer knitted fabric, retains loops already formed in the Nth layer, knits the stitches by passing a new thread through both the loops already formed and retained in the Nth layer and, of the loops retained in the (N−1)th layer, loops at corresponding positions to the loops already formed in the Nth layer, and releases the retention of the loops at the corresponding positions in accordance with the knitting of the stitches, while continuing to retain the loops already formed in the Nth layer even after completion of the knitting of the Nth layer knitted fabric. As a result, the knitting mechanism 7 knits the knitted product formed of the plurality of layers of knitted fabric in which two layers of knitted fabric that are adjacent in the top-bottom direction are joined by connecting loops at mutually corresponding positions.

Description

TECHNICAL FIELD

The present invention relates to a knitting machine and a knitting method for knitting a knitted product.

BACKGROUND ART

Conventionally, various techniques related to a knitting machine and a knitting method for knitting a knitted product have been proposed. For example, Patent Literature 1 describes a technique related to a knitting machine and a knitting method for knitting a knitted product used for covering a pipe or the like. The knitted product is formed of a three-dimensional knitted fabric curved in a tubular shape. Patent Literature 2 describes a technique related to a knitting machine and a knitting method for knitting a knitted product formed of a knitted fabric into which an inlay line is inserted.

Patent Literature 1: JP 2012-132109 A
Patent Literature 2: JP 2018-003176 A

SUMMARY OF INVENTION

Technical Problem

In the technical field related to knitting machines and knitting methods, there is a history in which knitted products in new modes have been provided with times, and knitting machines and knitting methods for knitting knitted products in new modes are always in demand.
The present invention has been made to solve such problems, and an object thereof is to provide a knitting machine and a knitting method capable of knitting a knitted product in a new mode.

Solution to Problem

In order to solve the above problem, a knitting machine according to the present invention includes a knitting mechanism that knits a knitted product by overlaying a knitted fabric in a plurality of layers. The knitting mechanism retains loops formed when knitting an (N−1)th-layer knitted fabric (N being an integer of 2 or more) even after the completion of the knitting of the (N−1)th-layer knitted fabric, and when knitting stitches in the Nth-layer knitted fabric, retains loops already formed in the Nth layer, knits stitches by passing a new thread through both the loops already formed and retained in the Nth layer and, of the loops retained in the (N−1)th layer, loops at corresponding positions to the loops already formed in the Nth layer, and releases retention of the loops at the corresponding positions in accordance with the knitting of the stitches while continuing to retain the loops already formed in the Nth layer even after completion of the knitting of the Nth-layer knitted fabric.

Advantageous Effects of Invention

According to the present invention configured as described above, when knitting stitches in the Nth layer, the stitches are formed by passing a thread through both loops already formed in an Nth layer and loops formed at corresponding positions in an (N−1)th layer. Therefore, a knitted product formed of a plurality of layers of knitted fabric, in which two layers of knitted fabric that are adjacent in the top-bottom direction are joined by connecting loops at mutually corresponding positions, can be knitted. The knitted product knitted as described above is a new mode of knitted product having a solid three-dimensional shape configured with a plurality of layers of knitted fabric. The present invention can provide a knitting machine and a knitting method capable of knitting a knitted product in this new mode.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an example of a knitted product knitted by a knitting machine according to a first embodiment of the present invention.

FIG. 2 illustrates an example of a knitting mechanism according to the first embodiment of the present invention.

FIG. 3 illustrates a needle.

FIG. 4 illustrates a needle cover.

FIG. 5 illustrates a cam.

FIG. 6 illustrates an opening/closing member.

FIG. 7 illustrates a system for elevating a holder block by a pusher.

FIG. 8 is a perspective view of a holder state changer and a holder.

FIG. 9 illustrates the holder state changer and a curved groove side holding piece.

FIG. 10 is a diagram illustrating a state of the holder and a change in the state.

FIG. 11 illustrates engagement of a driven gear with a main gear

FIG. 12 is a schematic view of a needle and the holder in the knitting mechanism.

FIG. 13 is a schematic view of the needle and the holder in the knitting mechanism.

FIG. 14 is a schematic view of a needle and a holder of the knitting mechanism.

FIG. 15 is a schematic view of the needle and the holder in the knitting mechanism.

FIG. 16 is a schematic view of the needle and the holder in the knitting mechanism.

FIG. 17 is a perspective view of the knitting mechanism.

FIG. 18 is a perspective view of the knitting mechanism.

FIG. 19 is a perspective view of the knitting mechanism.

FIG. 20 is a perspective view of the knitting mechanism.

FIG. 21 is a perspective view of the knitting mechanism.

FIG. 22 is a perspective view of the knitting mechanism.

FIG. 23 is a perspective view of the knitting mechanism.

FIG. 24 is a perspective view of the knitting mechanism.

FIG. 25 is a perspective view of the knitting mechanism.

FIG. 26 illustrates a catch used for routing a thread.

FIG. 27 illustrates thread routing and related operations.

FIG. 28 illustrates thread routing and related operations.

FIG. 29 illustrates stitches of a knitted fabric knitted by the knitting mechanism.

FIG. 30 illustrates another example of the needle.

FIG. 31 is a perspective view of a knitting mechanism according to a second embodiment of the present invention.

FIG. 32 is a top view and a side view of a knitting mechanism according to the second embodiment of the present invention.

FIG. 33 illustrates a paired needle.

FIG. 34 illustrates a holder forming member.

FIG. 35 illustrates a rear holder plate group.

FIG. 36 illustrates knitting of a knitted product.

FIG. 37 is a perspective view and a side view of the knitting mechanism.

FIG. 38 is a perspective view and a side view of the knitting mechanism.

FIG. 39 is a perspective view and a side view of the knitting mechanism.

FIG. 40 is a perspective view and a side view of the knitting mechanism.

FIG. 41 is a perspective view and a side view of the knitting mechanism.

FIG. 42 is a perspective view and a side view of the knitting mechanism.

FIG. 43 is a perspective view and a side view of the knitting mechanism.

FIG. 44 is a perspective view and a side view of the knitting mechanism.

FIG. 45 is a perspective view and a side view of the knitting mechanism.

FIG. 46 is a perspective view and a side view of the knitting mechanism.

FIG. 47 is a perspective view and a side view of the knitting mechanism.

FIG. 48 is a perspective view and a side view of the knitting mechanism.

FIG. 49 is a perspective view and a side view of the knitting mechanism.

FIG. 50 is a perspective view and a side view of the knitting mechanism.

FIG. 51 is a perspective view and a side view of a knitting mechanism.

FIG. 52 is a perspective view and a side view of the knitting mechanism.

FIG. 53 is a perspective view and a side view of the knitting mechanism.

FIG. 54 is a perspective view and a side view of the knitting mechanism.

FIG. 55 is a perspective view and a side view of the knitting mechanism.

FIG. 56 is a perspective view and a side view of the knitting mechanism.

FIG. 57 is a perspective view and a side view of the knitting mechanism.

FIG. 58 is a perspective view and a side view of the knitting mechanism.

FIG. 59 is a perspective view and a side view of the knitting mechanism.

FIG. 60 is a perspective view and a side view of the knitting mechanism.

FIG. 61 is a perspective view and a side view of the knitting mechanism.

FIG. 62 is a perspective view and a side view of the knitting mechanism.

FIG. 63 is a perspective view and a side view of the knitting mechanism.

FIG. 64 is a simplified front view of the rear holder plate group is viewed from the front in a simplified manner.

FIG. 65 is a side view of the knitting mechanism.

FIG. 66 is a side view of the knitting mechanism.

FIG. 67 is a diagram illustrating a modified example of the paired needle.

FIG. 68 is a side view of the knitting mechanism.

DESCRIPTION OF EMBODIMENTS

First Embodiment

Hereinafter, the first embodiment of the present invention will be described with reference to the drawings. FIG. 1 illustrates an example of a knitted product 2 knitted by a knitting machine 1 (FIG. 2) according to the present embodiment. As shown in FIG. 1, the knitted product 2 has a three-dimensional shape. The interior of the knitted product 2 is not hollow, and a thread 3 forming the knitted product 2 is filled inside. Therefore, even when a force is applied to the knitted product 2 from the outside (For example, when a force of crushing the knitted product 2 is applied to the knitted product 2 placed on a table), the shape of the knitted product 2 is less likely to be deformed as compared with a hollow knitted product. The knitting machine 1 according to the present embodiment is a device that knits the knitted product 2 having a three-dimensional shape whose interior is filled with thread 3 in a solid state, as illustrated in FIG. 1, instead of knitting a planar shape from a single sheet of knitted fabric. In the present embodiment, a state in which another loop has passed in a so-called wale direction through one loop in a knitted fabric is expressed as a “stitch”. Still more, passing a thread through one loop already formed is expressed as “knitting a stitch”. Knitting of the stitch results in forming a new loop. Furthermore, a looped thread through which another loop will be passed is referred to as a “loop”. A loop through which another loop has not yet passed and a loop through which another loop has already passed are both referred to as a “loop”.
FIG. 2 is a perspective view illustrating an internal structure of the knitting machine 1. In FIG. 2, the structure of components is simplified in consideration of convenience of description and ease of viewing the drawings, and some components are also omitted. In the following description of the knitting machine 1, as indicated by a double-headed arrow Y1 in FIG. 2, a direction in which a needle extender 5 (described later) of the needle 4 extends is defined as a front-back direction. One direction in the front-back direction is defined as front, and a direction opposite to the front is defined as back. Still more, as indicated by a double-headed arrow Y2 in FIG. 2, a direction intersecting the front-back direction and in which a holder block 6 (described later) is elevated and lowered is defined as a top-bottom direction. The top-bottom direction corresponds to a vertical direction when the knitting machine 1 is used in a normal manner. A direction directed vertically upward in the top-bottom direction is defined as upward and a direction directed vertically downward in the top-bottom direction is defined as downward. Further, as indicated by a double-headed arrow Y3 in FIG. 2, a direction orthogonal to the front-back direction on a horizontal plane perpendicular to the top-bottom direction is defined as a left-right direction. A right direction to the front in the left-right direction is defined as rightward, and a left direction to the front is defined as leftward.
As illustrated in FIG. 2, the knitting machine 1 is equipped with a knitting mechanism 7, and the knitting mechanism 7 includes a first needle unit 8, a second needle unit 9 provided behind the first needle unit 8, and a holder unit 10 provided between the first needle unit 8 and the second needle unit 9.
First, the first needle unit 8 will be described below. As illustrated in FIG. 2, the first needle unit 8 includes a flat sheet-like needle placement plate 12. The needle placement plate 12 is configured to be movable in the front-back direction within a predetermined range. On the upper surface of the needle placement plate 12, five needles 4 are arranged at intervals in the left-right direction.
FIG. 3(A) is an enlarged perspective view of the needle 4. As shown in FIG. 3(A), the needle 4 has two needle extenders 5 extending facing each other. This pair of needle extenders 5 are connected via a curved portion 13 at a base end. A hook 14 is provided at a tip of each of the two needle extenders 5. In other words, the needle 4 has forked hooks 14. As illustrated in FIG. 3(A), one hook 14 has a shape in which tips of two opposing claws come close to each other to form an inlet between the two claws, and a housing space communicating with the inlet is formed in an area surrounded by the two claws. The thread 3 (loop) can rest on the pair of hooks 14 of the needle 4. Still more, one needle extender 5 of the two needle extenders 5 is provided with a band 15 protruding in a direction orthogonal to the needle extender 5. The band 15 is integrally formed with the needle extender 5 by bending a material configuring the needle extender 5. Note that the shape of the needle 4 exemplified in FIG. 3(A) is merely an example. The needle 4 may have any shape as long as the tip can be opened and closed like tweezers (therefore, the state can be shifted between a gap state and a non-gap state to be described later) and a portion corresponding to the band 15 is connected. A modified example of the needle 4 will be described later with reference to FIG. 30.
FIGS. 3(B) and 3(C) are schematic views illustrating the needle 4 seen from the top in a simplified manner suitable for description. FIG. 3(B) shows the needle 4 in the gap state (described later), and FIG. 3(C) shows the needle 4 in the non-gap state (described later). As illustrated in FIG. 3(B), in a state that no external force is applied, the needle 4 is in the gap state in which a gap having a width T1 is formed between the pair of hooks 14 by an elastic force of the curved portion 13 and the needle extender 5. The width T1 is sufficiently larger than a width of a holder 16 to be described later. In the gap state, the holder 16 can enter between the pair of hooks 14. On the other hand, as illustrated in FIG. 3(C), the needle 4 can be brought into the non-gap state in which no gap or almost no gap is formed between the pair of hooks 14 by applying an external force to the pair of needle extenders 5 so that the needle extenders 5 approach each other.
Although not illustrated in FIG. 2, the needle placement plate 12 of the first needle unit 8 is provided with a needle cover 18. FIG. 4(A) is a schematic view illustrating the needle cover 18 of the first needle unit 8 seen from the top in a simplified manner suitable for description. In a state the needle cover 18 is attached to the needle placement plate 12, the needles 4 are not visible from the outside. In FIG. 4(A), the needles 4 are drawn by solid lines. In FIG. 4(A), the needles 4 are in a pull-back state (described later). As illustrated in FIG. 4(A), in the needle cover 18, a needle groove 19 is formed corresponding to the position of each of the needles 4 in the needle placement plate 12. The needle groove 19 includes a first groove 20 that extends in the front-back direction and houses a main body of the needle 4 except for the band 15 in a manner movable in the front-back direction, and a second groove 21 that is formed above the first groove 20 and houses the band 15 in a state movable in the front-back direction. The second groove 21 extends along the first groove 20.
A width of the first groove 20 is formed to be about the same as or slightly larger than the width of the needle 4 in the gap state. A height of the first groove 20 is formed to be about the same as or slightly larger than a height of the needle extender 5 of the needle 4. The second groove 21 is formed at a position corresponding to the position of the band 15 when the needle 4 is housed in the first groove 20, and when the needle 4 is housed in the needle groove 19, the band 15 protrudes to the outside of the needle cover 18 via the second groove 21. The needle 4 housed in the needle groove 19 in the needle cover 18 is movable in the front-back direction in a state where the movement in the left-right direction and the top-bottom direction are restricted. Furthermore, the needle 4 housed in the needle groove 19 can be moved in the front-back direction by applying a force for moving the needle 4 in the front-back direction to the band 15 protruding to the outside of the needle cover 18.
FIG. 4(B) is a cross-sectional view when the needle cover 18 and its related members are cut at a position of the second groove 21. As illustrated in FIGS. 4(A) and 4(B), a columnar protective member 22 is attached to the band 15 protruding to the outside of the needle cover 18 via the second groove 21. Note that the protective member 22 is not necessarily required. As illustrated in FIG. 4(A), a first regulating member 23 and a second regulating member 24 are provided on the upper surface of the needle cover 18. The first regulating member 23 abuts on the protective member 22 attached to the band 15 of the needle 4 at a predetermined position to restrict a backward movement of the needle 4. The second regulating member 24 abuts on the protective member 22 at a predetermined position to restrict a forward movement of the needle 4.
Although not illustrated in FIG. 2, a cam 26 is provided above the needle cover 18 of the first needle unit 8. FIG. 5(A) is a schematic top view illustrating the needle cover 18 of the first needle unit 8 showing the cam 26, the second groove 21, and the protective member 22 in a simplified manner suitable for describing the cam 26. The cam 26 is movable between a first cam position 27 (see FIG. 5(A)) located further on the left side than the leftmost second groove 21 and a second cam position 28 (see FIG. 5(C)) located further on the right side than the rightmost second groove 21. In FIG. 5(A), the cam 26 is located at the first cam position 27.
As illustrated in FIG. 5(A), a cam groove 29, which is inclined to move to the front while the cam 26 moves rightward, is formed in the cam 26. In FIG. 5(A) (the same applies to FIGS. 5(B) and 5(C) described later), the cam groove 29 is indicated on the cam 26 for convenience of description, but actually, the cam groove 29 is formed on a surface on the lower surface side (a surface facing the upper surface of the needle cover 18) of the cam 26, and thus the cam groove 29 is not visible when the cam 26 is seen from the top.
As illustrated in FIG. 5(A), when the cam 26 is located at the first cam position 27, all the needles 4 are in the pull-back state. When the cam 26 moves rightward from this state, the protective member 22 enters the cam groove 29 in order from the leftmost protective member 22 to the right side. The protective member 22 moves to the back side as the protective member 22 is guided by the cam groove 29 in line with the rightward movement of the cam 26, and then exits from the cam groove 29. In line with the movement of the protective member 22, the needles 4 in the pull-back state move backward and are brought into the push-out state. FIG. 5(B) illustrates a positional relationship between the protective member 22 and the cam 26 when the cam 26 is located substantially in the middle between the first cam position 27 and the second cam position 28. FIG. 5(C) illustrates a positional relationship between the protective member 22 and the cam 26 when the cam 26 is located at the second cam position 28. As described above, by moving the cam 26 from the first cam position 27 to the second cam position 28, the five needles 4 in the pull-back state are sequentially moved backward, and all the needles 4 can be brought into the push-out state.
On the other hand, when the cam 26 is located at the second cam position 28, all the needles 4 are in the push-out state. When the cam 26 moves leftward from this state until reaching the first cam position 27, the protective members 22 are guided by the cam groove 29, so that the five needles 4 in the push-out state sequentially move forward, and all the needles 4 are brought into the pull-back state.
As illustrated in FIG. 4, a sheet-like opening/closing member 30 is provided on the back surface of the needle cover 18 so as to cover the back surface. In FIG. 2, the opening/closing member 30 is not illustrated. FIG. 6(A) is a perspective view illustrating the opening/closing member 30 of the first needle unit 8, together with the needle cover 18. FIG. 6(B) is a schematic view illustrating a simplified positional relationship between the opening/closing member 30 located at a first opening/closing member position (described later) and the needle cover 18. FIG. 6(C) is a schematic view illustrating a simplified positional relationship between the opening/closing member 30 located at a second opening/closing member position (described later) and the needle cover 18. The opening/closing member 30 in FIG. 6(A) is located at the first opening/closing member position. In FIGS. 6(A) to 6(C), all the needles 4 are in the push-out state.
As illustrated in FIG. 6(A), at a lower end of the opening/closing member 30, five notches 31 penetrating the opening/closing member 30 in the front-back direction are formed and arranged at intervals in the left-right direction. As illustrated in FIG. 6(B), when the opening/closing member 30 is located at the first opening/closing member position, each of the five notches 31 is located at a position corresponding to an opening of the first groove 20 in the needle cover 18. In other words, the first opening/closing member position is a state in which each of the five notches 31 of the opening/closing member 30 is located at a position corresponding to the position of the opening of the first groove 20. As illustrated in FIGS. 6(A) and 6(B), when the opening/closing member 30 is located at the first opening/closing member position, no external force is applied to the needles 4 in the push-out state. Thus, the needles 4 in the push-out state are in the gap state.
The opening/closing member 30 is movable between the first opening/closing member position (FIGS. 6(A) and 6(B)) and the second opening/closing member position (FIG. 6(C)). When the opening/closing member 30 moves leftward from the first opening/closing member position and reaches the second opening/closing member position, as illustrated in FIG. 6(C), the needle extender 5 on the right side of the needle 4 in the push-out state is pushed leftward by an inner periphery of the notch 31, and the opening/closing member 30 in the push-out state shifts from the gap state to the non-gap state. As described above, by changing the position of the opening/closing member 30 to either the first opening/closing member position or the second opening/closing member position, the state of the needles 4 in the push-out state can be brought into either the gap state or the non-gap state.
As illustrated in FIG. 2, a pair of main gear supports 33 protruding upward are provided at two corners on the back side of the needle placement plate 12 of the first needle unit 8. On the right side of one of the main gear supports 33 located on the right side, a main gear 34 (its shaft center) is provided in a vertically movable manner. Similarly, on the left side of the main gear support 33 located on the left side, the main gear 34 (its shaft center) is provided in a vertically movable manner. The shaft centers of the pair of main gears 34 are connected to a drive shaft of a motor (different motors or one common motor may be provided to the pair of main gears 34) not illustrated in the drawing via a power transmission mechanism. The motor is driven to make the pair of main gears 34 revolve. The pair of main gears 34 revolve synchronously at the same revolving speed in the same revolving direction. The shaft centers of the pair of main gears 34 are configured to be movable in the top-bottom direction in synchronization between a gear upper limit position and a gear lower limit position.
As illustrated in FIG. 2, the first needle unit 8 is provided with a pair of pushers 35. One of the pushers 35 on the right side has a sheet-like push-up portion 36 extending along a horizontal plane, and a sheet-like attachment plate 37 connected to the right side of the push-up portion 36 and extending in the top-bottom direction. Similarly, the pusher 35 on the left side has a push-up portion 36 and an attachment plate 37 connected to the left end of the push-up portion 36. The pair of pushers 35 are configured to be synchronously movable in the front-back direction. Further, the push-up portions 36 are configured to be synchronously movable in the top-bottom direction between a pusher upper limit position and a pusher lower limit position with respect to the attachment plates 37. The pair of pushers 35 are members for selectively elevating or lowering the holder block 6 (detailed later). The operation of the pair of pushers 35 to elevate and lower the holder block 6 will be described later.
Although not illustrated in FIG. 2, the first needle unit 8 of the knitting mechanism 7 is mounted on a first drive mechanism. The first drive mechanism at least includes (1) a cam drive mechanism for moving the cam 26 between the first cam position 27 and the second cam position 28, (2) an opening/closing member drive mechanism for changing the position of the opening/closing member 30 between the first opening/closing member position and the second opening/closing member position, (3) a main gear-related drive mechanism for synchronously moving the shaft centers of the pair of main gears 34 in the top-bottom direction between the gear upper limit position and the gear lower limit position and also making the pair of main gears 34 revolve synchronously, and (4) a pusher drive mechanism for synchronously moving the pair of pushers 35 in the front-back direction and synchronously moving the pair of push-up portions 36 of the pair of pushers 35 in the top-bottom direction, and (5) a needle placement plate drive mechanism for moving the needle placement plate 12 in the front-back direction within a predetermined range. For example, the cam drive mechanism includes a carriage on which the cam 26 is mounted, a drive unit that causes the carriage to scan on a carriage shaft, a motor that drives the drive unit, a motor driver that controls the motor, and the like. Other mechanisms also include a drive unit that drives each mechanism, a motor the drives the drive unit, a motor driver that controls the motor, and the like. The knitting mechanism 7 of the knitting machine 1 includes a control unit 38 configured to include a microcontroller. The control unit 38 controls each part of the first drive mechanism. Each of the mechanisms (1) to (5) does not need to be mounted on a single first drive mechanism, and may be arranged in a distributed manner. In addition, each mechanism can be independently driven under the control of the control unit 38 instead of being synchronously driven in a predetermined manner.
The first needle unit 8 has been described above. The second needle unit 9 has the same structure as that of the first needle unit 8, and components having the same functions as that of the components of the first needle unit 8 are given the same reference signs as that of the first needle unit 8 to omit the description thereof. The second needle unit 9 is mounted on a second drive mechanism including at least the cam drive mechanism, the opening/closing member drive mechanism, the main gear-related drive mechanism, the pusher drive mechanism, and the needle placement plate drive mechanism. The control unit 38 controls each of the mechanisms in the second drive mechanism.
Next, the holder unit 10 will be described. As illustrated in FIG. 2, the holder unit 10 includes five holder blocks 6 arranged in the front-back direction. Each of the holder blocks 6 has a pair of bent members 40 disposed apart from each other in the left-right direction. In the pair of bent members 40, the bent member 40 on the right side has a rising portion 41 extending in the top-bottom direction and a contact portion 42 extending rightward from an upper end of the rising portion 41. Similarly, the bent member 40 on the left side of the pair of bent members 40 has a rising portion 41 and a contact portion 42 extending leftward from an upper end of the rising portion 41.
As illustrated in FIG. 2, the pair of bent members 40 support a holder support rod 43 extending in the left-right direction. The holder support rod 43 is a rod-like member, and its both ends are supported by the pair of rising portions 41 of the pair of bent members 40. A pair of holder state changers 44 are provided at both left and right ends of the holder support rod 43, and five holders 16 are arranged at intervals in the left-right direction between the pair of holder state changers 44.
When no external force is applied, a spring (not illustrated) applies a downward force to the holder block 6, and the holder block 6 is located at a block lower limit position. By applying a force to move the holder block 6 upward to the holder block 6 in this state, the holder block 6 can be moved in the top-bottom direction in a state where a movement of the holder block 6 is restricted in the front-back direction and the left-right direction.
The pair of pushers 35 can elevate or lower any one or two of the five holder blocks 6. More specifically, with respect to elevating and lowering of one holder block 6, the pair of pushers 35 are synchronously movable in the front-back direction, as described above, and also the pair of push-up portions 36 of the pair of pushers 35 are synchronously movable in the top-bottom direction. For example, to elevate one holder block 6, the control unit 38 controls the pusher drive mechanism to adjust the positions of the pair of pushers 35 in the front-back direction such that the upper surface of each of the push-up portions 36 of the pair of pushers 35 (either the first needle unit 8 or the second needle unit 9) and the lower surface of each of the pair of contact portions 42 of the one holder block 6 face each other. FIG. 7(A) is a schematic view illustrating a positional relationship between the pair of bent members 40 of the one holder block 6 and the pair of pushers 35 in this state.
After this state, the control unit 38 controls the pusher drive mechanism to elevate the pair of push-up portions 36 upward with respect to the pair of attachment plates 37. According to the upward movement of the pair of push-up portions 36, the upper surfaces of the push-up portions 36 of the pair of pushers 35 and the lower surfaces of the pair of contact portions 42 of the one holder block 6 come into contact with each other at a predetermined timing. FIG. 7(B) is a schematic view illustrating a positional relationship between the pair of bent members 40 of the one holder block 6 and the pair of pushers 35 in this state. After this state, as the pair of push-up portions 36 further moves upward, the pair of bent members 40 are elevated upward by the pair of push-up portions 36, whereby the one holder block 6 moves upward. Note that, by positioning the pushers 35 between two adjacent bent members 40 in the front-back direction, the pair of pushers 35 can simultaneously elevate the two holder blocks 6.
As described above, the holder unit 10 includes the five holder blocks 6 arranged in the front-back direction, and the holder block 6 includes the pair of holder state changers 44 provided at both ends of the holder support rod 43 and the five holders 16 provided between the pair of holder state changers 44. As illustrated in FIG. 2, a needle 4A provided on the leftmost side of the first needle unit 8 and a needle 4B provided on the leftmost side of the second needle unit 9 are arranged on substantially the same straight line, and five holders 16 of five different holder blocks 6 are arranged spaced apart from each other in the front-back direction on this straight line. Thus, when the front-back direction is defined as a “column direction”, the knitting mechanism 7 has a column group including the pair of needles 4 facing each other in the column direction, and the holders 16 arranged in five rows in the column direction on substantially the same straight line as the pair of needles 4. In the knitting mechanism 7, five column groups are provided spaced apart in the left-right direction.
FIG. 8(A) is a perspective view, when seen from a predetermined viewpoint, of the holder state changer 44 provided on the left side in the pair of holder state changers 44 of one holder block 6, and the holder 16 provided at a position nearest to the holder state changer 44. FIG. 8(B) is a perspective view of the holder state changer 44 and the holder 16 when seen from a viewpoint different from that in FIG. 8(A). In FIGS. 8(A) and 8(B) (also each drawing in FIG. 10 described later), the holder state changer 44 is cut at a position rightward for a predetermined distance from the holder 16. In FIG. 8(B), some components are seen though in the drawing. In FIGS. 8(A) and 8(B) (also each drawing in FIG. 10 described later), the holder state changer 44 and the holder 16 are closer to each other than those in FIG. 2 for convenience of description. However, a distance between the holder state changer 44 and the holder 16 does not affect the operation of the holder state changer 44 and the holder 16. Hereinafter, in the pair of holder state changers 44 of one holder block 6, the holder state changer 44 provided on the left side and its related members will be described with reference to FIG. 8 and FIGS. 9 and 10 to be described later.
As illustrated in FIGS. 8(A) and 8(B), the holder state changer 44 is a substantially cylindrical, and a driven gear 45 is provided at an end on the left side. Although gear teeth of the driven gear 45 are not illustrated in FIGS. 8(A) and 8(B) (also each drawing in FIG. 10 described later), the gear teeth are actually formed on an outer periphery of the driven gear 45 as illustrated in FIG. 2. The driven gear 45 is a part of the holder state changer 44, and can make the holder state changer 44 revolve about the holder support rod 43 by making the driven gear 45 revolve. As described later, the driven gear 45 is engaged with the main gear 34, and the driven gear 45 revolves following the revolution of the main gear 34.
A through hole 44 a is formed in a central axis of the holder state changer 44, and the holder support rod 43 passes through the through hole 44 a in a state that an outer periphery of the holder support rod 43 is in contact with an inner periphery of the through hole 44 a. With this structure, in a state that no external force is applied to the holder state changer 44, a posture of the holder state changer 44 is retained with respect to the holder support rod 43 by a frictional force acting between the inner periphery of the through hole 44 a and the outer periphery of the holder support rod 43. On the other hand, when an external force, against the frictional force, for revolving the holder state changer 44 is applied to the holder state changer 44, the holder state changer 44 revolves about the holder support rod 43.
As shown in FIGS. 8(A) and 8(B) (particularly in FIG. 8(A)), on the holder support rod 43, a cylindrical intervening member 47 with a predetermined length is provided on the right side of a surface 46 on the right side of the holder state changer 44. The holder 16 (detailed structure will be described later) is provided on the right side of the intervening member 47, and an intervening member 48 is provided on the right side of the holder 16. The holder 16 is sandwiched between the intervening member 47 and the intervening member 48. These members position the holder 16 in the left-right direction on the holder support rod 43. Other holders 16 provided on the holder support rod 43 are also positioned on the holder support rod 43 by intervening members interposed between the holder 16 and the holder 16 and between the holder 16 and the holder state changer 44.
FIG. 9(A) is a schematic front view illustrating the surface 46 on the right side of the holder state changer 44 in the states in FIGS. 8(A) and 8(B) (hereinafter, referred to as a “normal state” for convenience). As illustrated in FIGS. 8(A) and 9(A), in the normal state of the surface 46 on the right side of the holder state changer 44, a gently curved opening is formed on the right side of the center of the surface 46 when seen from the front. A curved groove 50 communicating with this opening is formed in the holder state changer 44. A curved groove insertion rod 52 is inserted into the curved groove 50.
More specifically, a tip part of the curved groove insertion rod 52 is inserted into the curved groove 50 in a state that the curved groove insertion rod 52 is supported by a curved groove side holding piece 54 (described later) of the holder 16. As described later, the position of the curved groove side holding piece 54 with respect to the holder support rod 43 is retained by a frictional force acting between the curved groove side holding piece and the holder support rod 43.
As illustrated in FIGS. 8(A) and 9(A), in the normal state of the surface 46 on the right side of the holder state changer 44, a circular opening is formed on the left side with respect to the center of the surface 46 when seen from the front. A holding hole 51 communicating with this opening is formed in the holder state changer 44. A holding hole insertion rod 53 is inserted into the holding hole 51. The size of an inner periphery of the holding hole 51 is substantially the same as the size of an outer periphery of the holding hole insertion rod 53. The holding hole insertion rod 53 is inserted into and supported by the holding hole 51 in a state that the position of the holding hole insertion rod 53 relative to the holder state changer 44 is fixed.
As illustrated in FIGS. 8(A) and 8(B), the holder 16 includes the curved groove side holding piece 54 and a holding hole side holding piece 55. The shape of the curved groove side holding piece 54 and the shape of the holding hole side holding piece 55 are substantially the same. FIG. 9(B) is a schematic front view illustrating the curved groove side holding piece 54. As illustrated in FIG. 9(B), the curved groove side holding piece 54 has an outer circumference on an arc, and a central extension portion 56 protrudes from a central portion thereof. A through hole 57 through which the holder support rod 43 passes is formed at a tip part of the central extension portion 56, and a through hole 58 through which the curved groove insertion rod 52 passes is formed at a base part of the central extension portion 56. On both sides of the central extension portion 56, two claws 59 are formed, and recesses are formed between the claws 59 and the central extension portion 56. Since the holding hole side holding piece 55 has substantially the same shape as the curved groove side holding piece 54, the same components as those of the curved groove side holding piece 54 are given the same reference signs as that of the curved groove side holding piece 54 to omit the description thereof.
As illustrated in FIGS. 8(A) and 8(B), in the curved groove side holding piece 54, the holder support rod 43 passes through the through hole 57 (FIG. 9(B)) in the central extension portion 56. Unless a force is externally applied to the curved groove side holding piece 54, the position of the curved groove side holding piece 54 with respect to the holder support rod 43 is retained by a frictional force acting between the outer periphery of the holder support rod 43 and the inner periphery of the through hole 57. Still more, the curved groove insertion rod 52 passes through the through hole 58 (FIG. 9(B)). As described above, the curved groove side holding piece 54 supports the curved groove insertion rod 52. Similarly, in the holding hole side holding piece 55, the holder support rod 43 passes through the through hole 57 in the central extension portion 56, and the holding hole insertion rod 53 passes through the through hole 58. As illustrated in FIGS. 8(A) and 8(B), one of the claws 59 of the curved groove side holding piece 54 and one of the claws 59 of the holding hole side holding piece 55 are located at corresponding positions, and one holding part 60 is formed by these claws 59. In addition, the other of the claws 59 of the curved groove side holding piece 54 and the other of the claws 59 of the holding hole side holding piece 55 are located at corresponding positions, and one holding part 60 is formed by these claws 59. In this manner, the holder 16 has two holding parts 60. The two holding parts 60 are disposed at symmetrical positions about the holder support rod 43 (symmetric point). The holder 16 is revolvable about the holder support rod 43 (symmetric point) while retaining a state in which the positions of the two holding parts 60 are symmetric about the holder support rod 43 (symmetric point).
The holder state changer 44 can bring the holder 16 into any of a lower closed state, a both closed state, and an upper closed state. FIG. 10 illustrates each state of the holder 16 and a first revolving operation, a second revolving operation, and a third revolving operation to be described later. FIG. 10(A) illustrates the holder 16 in the lower closed state. As shown in FIG. 10(A), in the lower closed state, one of the holding parts 60 is located above the holder support rod 43, and the other of the holding parts 60 is located below the holder support rod 43. In the following description, in the state that one holding part 60 is located above and the other holding part 60 is located below the holder support rod 43, the holding part 60 on the upper side is referred to as an upper holding part 60U, and the holding part 60 on the lower side is referred to as a lower holding part 60D. As illustrated in FIG. 10(A), in the lower closed state, a tip of the claw 59 of the curved groove side holding piece 54 and a tip of the claw 59 of the holding hole side holding piece 55 are separated from each other in the upper holding part 60U. A housing space 61 surrounded by the claws 59 is opened via an inlet formed between the claws 59. Hereinafter, this state is referred to as an “open state”.
On the other hand, in the lower closed state, a tip of the claw 59 of the curved groove side holding piece 54 and a tip of the claw 59 of the holding hole side holding piece 55 in the lower holding part 60D cross each other, and an outer periphery of a housing space 61 surrounded by these claws 59 is closed. Hereinafter, this state is referred to as a “grip state”. When the holding part 60 is brought into the grip state in a state that a loop of the thread 3 is inserted into the housing space 61, the loop does not come off the housing space 61, and the loop can be retained by the holding part 60. When the holding part 60 is in the grip state, the loop can be retained regardless of the position of the holding part 60. FIG. 10 (B) illustrates the holder 16 in the both closed state. As shown in FIG. 10(B), in the both closed state, both the upper holding part 60U and the lower holding part 60D are in the grip state. FIG. 10(C) illustrates the holder 16 in the upper closed state. As illustrated in FIG. 10(C), in the upper closed state, the upper holding part 60U is in the grip state, and the lower holding part 60D is in the open state.
The holder state changer 44 can change the state of the holder 16 in a predetermined manner by performing the first revolving operation, the second revolving operation, or the third revolving operation. Hereinafter, the first revolving operation, the second revolving operation, and the third revolving operation will be described. Now, let's say that the state of the holder 16 and the holder state changer 44 is in the state illustrated in FIG. 10(B). In FIG. 10(B), the holder 16 is in the both closed state, and the curved groove insertion rod 52, the holding hole insertion rod 53, and the holder support rod 43 are positioned on substantially the same horizontal plane. When the holder state changer 44 revolves by about 30° in a revolving direction KD1 from the state in FIG. 10(B), the state of the holder 16 and the holder state changer 44 becomes the state in FIG. 10(A). In FIG. 10(A), the holder 16 is in the lower closed state. In other words, when the holder state changer 44 is revolved by about 30° in the revolving direction KD1 from the state in FIG. 10(B), the holder 16 shifts from the both closed state to the lower closed state. This is because of the following reason.
More specifically, when the holder state changer 44 revolves in the revolving direction KD1 from the state in FIG. 10(B), the holding hole side holding piece 55 revolves for the same amount as the revolving amount of the holder state changer 44 according to the revolution of the holder state changer 44 in the revolving direction KD1. This is because the holding hole insertion rod 53 inserted into the holding hole 51 revolves in synchronization with the revolution of the holder state changer 44, and the holding hole side holding piece 55 revolves about the holder support rod 43 as the holding hole insertion rod 53 revolves. On the other hand, the curved groove side holding piece 54 does not revolve in accordance with the revolution of the holder state changer 44 in the revolving direction KD1. This is because, while the holder state changer 44 revolves, the curved groove insertion rod 52 moves inside the curved groove 50 without coming into contact with the inner periphery of the curved groove 50. Therefore, no external force is applied to the curved groove insertion rod 52. When no external force is applied to the curved groove insertion rod 52, no external force is applied to the curved groove side holding piece 54. Thus, the position of the curved groove side holding piece 54 does not change. As described above, according to the revolution of the holder state changer 44 by about 30° in the revolving direction KD1, the holding hole side holding piece 55 revolves but the curved groove side holding piece 54 does not revolve. Therefore, the holder 16 shifts from the both open state illustrated in FIG. 10(B) to the lower closed state illustrated in FIG. 10(A).
Then, from the state in FIG. 10(A), the holder state changer 44 revolves in a revolving direction KD2 by about 210° to change the state of the holder 16 as illustrated in FIG. 10(A)→FIG. 10(B)→FIG. 10(C)→FIG. 10(D)→FIG. 10(E). This is the first revolving operation. More specifically, when the holder state changer 44 revolves by about 30° in the revolving direction KD2 from the state in FIG. 10(A), the holder 16 shifts to the both closed state as illustrated in FIG. 10(B). This is because the holding hole side holding piece 55 revolves in synchronization with the revolution of the holder state changer 44 but the curved groove side holding piece 54 does not revolve. When the holder state changer 44 further revolves in the revolving direction KD2 by about 30° from the state in FIG. 10(B), the holder 16 shifts to the upper closed state as illustrated in FIG. 10(C). This is because the holding hole side holding piece 55 revolves in synchronization with the revolution of the holder state changer 44 but the curved groove side holding piece 54 does not revolve. In the state in FIG. 10(C), the curved groove insertion rod 52 comes into contact with the inner periphery (or is slightly separated from the inner periphery) at the end of the curved groove 50.
When the holder state changer 44 further revolves in the revolving direction KD2 from the state in FIG. 10(C), not only the holding hole side holding piece 55 but also the curved groove side holding piece 54 will revolve in synchronization with the holder state changer 44. This is because the inner periphery at the end of the curved groove 50 abuts on the curved groove insertion rod 52, and an external force for revolving the curved groove insertion rod 52 is applied to the curved groove insertion rod 52 in synchronization with the revolution of the holder state changer 44. Therefore, the upper holding part 60U in the grip state in FIG. 10(C) moves in the revolving direction KD2 while retaining the grip state. On the other hand, the lower holding part 60D in the open state in FIG. 10(C) moves in the revolving direction KD2 while retaining the open state. FIG. 10(D) illustrates the states of the holder 16 and the holder state changer 44 when the holder state changer revolves in the revolving direction KD2 by about 15° from the state in FIG. 10(C).
When the revolution further proceeds in the revolving direction KD2 from the state in FIG. 10(D), as illustrated in FIG. 10(E), the holding part 60 that has been the upper holding part 60U in FIG. 10(C) becomes the lower holding part 60D while retaining the grip state, and the holding part 60 that has been the lower holding part 60D in FIG. 10(C) becomes the upper holding part 60U while retaining the open state. The operation of changing the state of the holder 16 from the state in FIG. 10(A) to the state in FIG. 10(E) is the first revolving operation. As described above, when the holder state changer 44 performs the first revolving operation, the state changes in order of lower closed state→both closed state→upper closed state. Then, the upper holding part 60U in the grip state becomes the lower holding part 60D while retaining the grip state, and the lower holding part 60D in the open state becomes the upper holding part 60U while retaining the open state.
The second revolving operation is an operation in which the holder state changer 44 revolves by about 30° in the revolving direction KD1 from the state in FIG. 10(E). The upper holding part 60U shifts from the open state to the grip state, and the lower holding part 60D shifts from the grip state to the open state as illustrated in FIG. 10(F).
The third revolving operation is an operation in which the holder state changer 44 revolves by about 150° in the revolving direction KD1 from the state in FIG. 10(F) to change the state of the holder 16 in the following manner. More specifically, in the state in FIG. 10(F), the upper holding part 60U of the holder 16 is in the grip state, and the lower holding part 60D is in the open state. When the holder state changer 44 performs the third revolving operation, the upper holding part 60U in the grip state becomes the lower holding part 60D while retaining the grip state, and the lower holding part 60D in the open state becomes the upper holding part 60U while retaining the open state.
As illustrated in FIG. 2, a pair of holder state changers 44 are provided at both ends of the holder support rod 43. The pair of holder state changers 44 have a bilaterally symmetrical structure in a front view. The curved groove 50 in one of the holder state changers 44 and the curved groove 50 in the other of the holder state changers 44 face each other, and also the holding hole 51 in the one holder state changer 44 and the holding hole 51 in the other holder state changer 44 face each other. A common curved groove insertion rod 52 is inserted into the pair of curved grooves 50 in the pair of holder state changers 44, and a common holding hole insertion rod 53 is inserted into the pair of holding holes 51 in the pair of holder state changers 44.
The control unit 38 controls the main gear-related drive mechanism and the pusher drive mechanism to change the state of the holder 16 by making the holder state changers 44 revolve. In particular, the control unit 38 can cause the holder state changers 44 to perform the first revolving operation, the second revolving operation, or the third revolving operation. More specifically, the control unit 38 moves one of the holder blocks 6 whose state of the holder 16 is to be changed upward for a predetermined amount by the pair of pushers 35 of the first needle unit 8 or the second needle unit 9. Furthermore, the control unit 38 moves the needle placement plate 12 of the first needle unit 8 or the second needle unit 9 forward for a predetermined amount, adjusts the vertical position of the shaft center of the pair of main gears 34, and engages the pair of main gears 34 with the pair of driven gears 45 of the one of the holder blocks 6.
FIG. 11 illustrates a state in which the driven gear 45 and the main gear 34 are engaged. In FIG. 11, the holder unit 10 from which the bent member 40 on the left side is removed is viewed from left to right. After the pair of driven gears 45 and the pair of main gears 34 are engaged, the control unit 38 makes the pair of main gears 34 revolve in an appropriate revolving direction for a necessary revolving amount to change the holder 16 from the current state to the target state. Along with the revolution of the pair of main gears 34, the pair of holder state changers 44 revolve in synchronization with the pair of driven gears 45 in an appropriate revolving direction for an appropriate revolving amount to synchronously change the state of the five holders 16 provided in one holder block 6.
In addition, the holder unit 10 includes a catch drive mechanism (not illustrated) described later. As described later, the control unit 38 controls the catch drive mechanism to arrange the thread 3 on knitting the knitted product 2. Still more, the knitting mechanism 7 of the knitting machine 1 includes a thread supply mechanism that houses a bobbin around which the thread 3 is wound and supplies the thread 3 to the knitting mechanism 7. FIG. 2 illustrates the state of the thread 3 wound around the bobbin.
Next, an operation when the knitting mechanism 7 of the knitting machine 1 knits the knitted product 2 will be described. Hereinafter, a basic operation flow of the knitting machine 1 will be described using schematic views illustrating the needle 4, the holder 16, and the thread 3, and also specific states of the knitting machine 1 will be shown using perspective views as appropriate. FIGS. 12 to 16 are schematic views illustrating the operation flow for knitting a knitted product by the knitting mechanism 7. FIGS. 17 to 25 are perspective views of the knitting mechanism 7. In FIGS. 12 to 16 and FIGS. 17 to 25, directions follow directions indicated by arrows in the drawings.
In the schematic views in FIGS. 12 to 16, such as in FIG. 12(A), a state of the column group including the needle 4A (the needle 4 on the leftmost side) of the first needle unit 8 in FIG. 2 and the needle 4B (the needle 4 on the leftmost side) of the second needle unit 9 is schematically illustrated as seen from the side. In this column group, five rows from the first row to the fifth row are formed from the needle 4B toward the needle 4A in the column direction (front-back direction). A holder H1 is provided in the first row, a holder H2 is provided in the second row, a holder H3 is provided in the third row, a holder H4 is provided in the fourth row, and a holder H5 is provided in the fifth row. In the perspective views, reference signs H1 to H5 are indicated only in FIG. 17(A).
Further, the holder block 6 having the holder H1 is a holder block B1, the holder block 6 having the holder H2 is a holder block B2, the holder block 6 having the holder H3 is a holder block B3, the holder block 6 having the holder H4 is a holder block B4, and the holder block 6 having the holder H5 is a holder block B5. In the perspective views, reference signs B1 to B5 are indicated only in FIG. 17(A). As described above, the knitting mechanism 7 includes five column groups, and the column groups other than the column group illustrated in the schematic views also perform the same operation as the column group illustrated in the schematic views.
FIGS. 17 to 25 are basically perspective views of the knitting mechanism 7 of the knitting machine 1 shown in FIG. 2 as seen from the left oblique rear side toward the holder unit 10, with some exceptions. However, for the sake of visibility of the drawings, five bent members 40 arranged on the left side of the holder unit 10, all the pushers 35, and the main gear support 33 (and members related thereto) arranged on the left side are not illustrated. In the following description, an expression “state in FIG. o” refers to a combination of the state of the knitting mechanism 7 and the state of the thread 3 retained by the knitting mechanism 7. Still more, an expression “Fig. ∘ (provided that any of FIGS. 17 to 25) corresponds to Fig. Δ (provided that any of FIGS. 12 to 16)” means that FIG. ∘ is a perspective view specifically illustrating the state of the knitting mechanism 7 shown in Fig. Δ.
Still more, in the following description, when the control unit 38 moves a member or changes a state of a member, a detailed description of a specific operation performed by each mechanism may be omitted. For example, when the control unit 38 controls the pusher drive mechanism and other related mechanisms to move the pusher 35, and thereby elevating (lowering) the holder 16, it is simply expressed as “The control unit 38 elevates (lowers) the holder 16”. Furthermore, for example, when the control unit 38 controls the needle placement plate drive mechanism and other related mechanisms to move the needle placement plate 12 forward (or backward), thereby moving the needle 4 (for example, needle 4A) forward (or backward), it is simply expressed as “The control unit 38 moves the needle 4 forward”.
Before describing details of the operation of the knitting mechanism 7, a rough flow of knitting the knitted product 2 by the knitting mechanism 7 will be described. The knitting mechanism 7 knits a first-layer knitted fabric (stitches are knitted on a plurality of rows in a plurality of columns), and then knits a second-layer knitted fabric such that the second layer knitted fabric is overlaid on the first layer knitted fabric. The knitting mechanism 7 continues to overlay more layers of the knitted fabric after the second layer to knit the knitted product 2 with a plurality of layers of knitted fabric.
First, the knitting mechanism 7 is set to the state in FIG. 12(A). FIG. 17(A) corresponds to FIG. 12(A). As illustrated in FIG. 17(A), in the state in FIG. 12(A), a so-called a cast-on loop is held by the lower holding part 60D in the grip state of the holder H1. However, in the schematic views, including FIG. 12(A), the cast-on loop held by the holder H1 is omitted for ease of viewing the drawing. As illustrated in FIGS. 12(A) and 17(A), in the state in FIG. 12(A), the lower holding part 60D in the grip state of the holder H2 retains a loop passed through a loop retained by the holder H1. In the present example, the state in FIG. 12(A) is achieved by manually winding the thread 3 supplied by the thread supply mechanism. However, a process to achieve the state in FIG. 12(A) may be partially automated. In the state in FIG. 12(A), vertical positions of all the holders 16 are lower than vertical positions of the needles 4A and 4B. Hereinafter, the vertical position of the holder 16 in FIG. 12(A) is referred to as a “lower limit holder position”.
From the state in FIG. 12(A), the control unit 38 elevates the holder H2 to shift to the state in FIG. 12(B). FIG. 17(B) corresponds to FIG. 12(B). A vertical position of the holder H2 in FIG. 12(B) is located above vertical positions of the needles 4A and 4B. Hereinafter, the vertical position of the holder H2 in FIG. 12(B) is referred to as an “upper limit holder position”.
Then, the thread 3 is routed. FIG. 18(A) is a perspective view showing the knitting mechanism 7 after the thread 3 is routed. As illustrated in FIG. 18(A), in routing of the thread 3, after the thread 3 is drawn out from the thread supply mechanism, a routed portion 62 is arranged from the thread 3 drawn out up to a loop retained by the holder 16 on the rightmost side of the holder block B2 (the holder 16 circled with a solid line in FIG. 18(A)), to achieve the state illustrated in FIG. 18(A).
As shown in FIG. 18(A), the routed portion 62 includes a first vertically extending portion 63 extending upward from a position connected to the loop retained by the holder 16 on the rightmost side of the holder block B2, a first horizontally extending portion 64 from the first vertically extending portion 63 bent at an upper end and extending leftward, a second vertically extending portion 65 from the first horizontally extending portion 64 bent at a left end and extending upward, a second horizontally extending portion 66 from the second vertically extending portion 65 bent at an upper end and extending rightward, and a second vertically extending portion 67 bent at a right end and extending downward from the second horizontally extending portion 66.
In FIG. 18(A), a catch (FIG. 26) to which the thread 3 is hooked is provided at a point A, a point B, a point C, a point D, and a point E. The routed portion 62 is brought into the state in FIG. 18(A) by hooking the thread 3 to the catch at each point. The holder unit 10 includes a catch drive mechanism that changes the position of each catch in a predetermined manner within a predetermined range. The control unit 38 can change the position of each catch according to a predetermined manner within a predetermined range by controlling the catch drive mechanism. After the thread 3 is hooked to each catch, the thread 3 is routed by moving each catch to an appropriate position in an appropriate manner under the control of the control unit 38.
FIG. 26 is a schematic view illustrating, in a simplified manner, catches KA, KB, KC, KD, KE to which the thread 3 is hooked at the points A, B, C, D, and E in FIG. 18(A). In an example in FIG. 26, a plate member IT provided with the catch KA and the catch KE is provided below the holder unit 10 to hook the thread 3 with the catch KA at a point A′ corresponding to the point A. Still more, the thread 3 is hooked to the catch KB at a point B′ corresponding to the point B. In the example in FIG. 26, the catch KB is a needle-shaped member in which a hook is formed. The thread 3 is hooked to the catch KC at a point C′ corresponding to the point C. The thread 3 is hooked to the catch KD at a point D′ corresponding to the point D. The thread 3 is hooked to the catch KE at the point E′ corresponding to the point E.
After the thread 3 is routed, the control unit 38 brings the needle 4A into the push-out state. Next, the control unit 38 brings the needle 4A into the non-gap state, and moves the needle 4A in the non-gap state backward while allowing the needle 4A to pass through the loop held by the holder H2 (loop lifted by the holder H2) located at the upper limit holder position. The control unit 38 moves the needle 4A forward until a portion of the needle 4A farther front of the hooks 14 reaches below the first horizontally extending portion 64 of the routed portion 62. Since the needle 4A is in the non-gap state, the thread 3 does not enter between the pair of hooks 14, and the needle 4A can smoothly move backward while passing through the loop. Note that, in the following description, even in a case not specifically described, when the control unit 38 passes the needle 4 through the loop, the needle 4 is in the non-gap state at least at the timing when the needle 4 enters the loop.
Next, the control unit 38 controls the catch drive mechanism to move the first horizontally extending portion 64 downward. When the downward movement of the first horizontally extending portion 64 advances, the thread 3 enters the hooks 14 by a predetermined operation, and the thread 3 rests on the hooks 14 (FIG. 12(C)). FIG. 18(B) corresponds to FIG. 12(C).
Now, an operation until the thread 3 corresponding to the first horizontally extending portion 64 rests on the hooks 14 of the needle 4A after the thread 3 is routed will be briefly described. FIGS. 27 and 28 simply illustrate the operation from the routing of the thread 3 to resting of the thread 3 corresponding to the first horizontally extending portion 64 on the hooks 14 of the needle 4A, assuming that the catches to which the thread 3 is hooked are the catches KA to KE exemplified in FIG. 26. FIG. 27(A) shows a state that the thread 3 is hooked to the catch KA. Then, the catch KE is operated to hook the thread 3 in a state illustrated in FIG. 27(B). The catch KE is revolvable about a shaft center connected to the plate member IT.
Next, the catch KB lowers downward to such an extent that a hook formed at its tip on the lower side reaches below the thread 3 (FIG. 27(C)), and then the catch KB rises to hook the thread 3, and lifts the thread 3 upward (FIG. 27(D)). Next, a tip of the catch KC enters a loop formed by lifting the thread 3 upward by the catch KB in a state illustrated in FIG. 27(E). Next, as illustrated in FIG. 27(F), the catch KF hooks the thread 3 as illustrated in FIG. 27(F), and at the same time, the catch KC moves as illustrated in FIG. 27(F) in a state that the thread 3 is hooked by a hook of the catch KC. In the state in FIG. 27(F), the thread 3 is hooked in the order of the catch KA, the catch KB, the catch KC, the catch KF, and the catch KE.
Then, the catch KF moves in a manner as illustrated in FIG. 28(A), and the catch KD moves upward so as to enter a loop formed by the thread 3 being pulled by the catch KC (FIG. 28(A)). Next, as illustrated in FIG. 28(B), the catch KD moves downward while the thread 3 is hooked, and the needle 4A moves backward so as to pass below a portion of the thread 3 sandwiched between the catch KD and the catch KF (portion corresponding to the first horizontally extending portion 64). Then, the catch KF moves in a manner as illustrated in FIG. 28(C), and the catch KF releases the thread 3 that has been held. Then, as illustrated in FIG. 28(C), a portion of the thread 3 sandwiched between the catch KD and the catch KF (portion corresponding to the first horizontally extending portion 64) moves downward, and is brought into a state of being in contact with a portion farther front of the hooks 14 of the needle 4A. When the needle 4A moves backward from the state in FIG. 28(C), the thread 3 rests on the hooks 14 of the needle 4A as illustrated in FIG. 28(D).
After the state in FIG. 12(C) is achieved, the control unit 38 moves the needle 4A forward while allowing the needle 4A to pass through a loop retained by the holder H2. The control unit 38 moves the needle 4A forward until the hooks 14 of the needle 4A reach above the holder H3 (FIG. 12(D)). FIG. 19(A) corresponds to FIG. 12(D). The operation of shifting from the state in FIG. 12(B) to the state in FIG. 12(D) corresponds to the operation of knitting stitches on the second row in the first-layer knitted fabric. More specifically, the operation of shifting the state in FIG. 12(B) to the state in FIG. 12(D) corresponds to the operation of knitting a stitch on the second row by passing the thread 3 through the loop on the second row formed by knitting the stitch on the first row (a row immediately preceding the second row in the first layer) when knitting stitches on the second row at the time of knitting the first-layer knitted fabric. A new loop (loop on the third row) is formed according to knitting of the knitted stitch. In the first layer, stitches are knitted stepwise in a direction from the first row to the fifth row. Therefore, for example, in the first layer, a row immediately preceding the second row is the first row, and a row immediately preceding the fifth row is the fourth row. On the other hand, in the second layer, stitches are knitted stepwise in a direction from the fifth row to the first row. Therefore, for example, a row immediately preceding the fourth row is the fifth row, and a row immediately preceding the second row is the third row.
After the state in FIG. 12(D) is achieved, the control unit 38 transfers the loop from the needle 4A to the holder H3 (FIG. 12(E)). FIG. 19(B) corresponds to FIG. 12(E). In FIG. 19(B), the holder block B2 is not illustrated for ease of viewing of the drawing. To transfer the loop from the needle 4A to the holder H3, in detail, the control unit 38 brings the needle 4A into the gap state. When the needle 4A is brought into in the gap state, the thread 3 is retained across the pair of hooks 14. Next, the control unit 38 brings the holder H3 into the lower closed state. In other words, the control unit 38 opens the upper holding part 60U of the holder H3. Next, the control unit 38 moves the holder H3 in the lower closed state upward to a predetermined position.
As described with reference to FIG. 3(B), the length T1 of the gap formed between the pair of hooks 14 of the needle 4A in the gap state is larger than the width of the holder 16. Therefore, as the holder H3 in the lower closed state moves upward, the upper holding part 60U in the open state of the holder H3 enters between the pair of hooks 14. At this point, the thread 3 retained across the pair of hooks 14 will be housed in the housing space 61 of the upper holding part 60U via the inlet. The control unit 38 elevates the holder H3 until the thread 3 is lifted to such an extent that the thread 3 retained in the pair of hooks 14 is released. Then, the control unit 38 stops elevating the holder H3. The above is the operation for transferring the loop from the needle 4A to the holder H3.
Then, the control unit 38 moves the needle 4A forward (FIG. 12(F)) and causes the pair of holder state changers 44 in the holder block B3 to perform the first revolving operation. When the holder state changers 44 perform the first revolving operation, the upper holding part 60U that holds the loop in the open state shifts to the grip state while holding the loop, and the upper holding part 60U becomes the lower holding part 60D. In other words, the lower holding part 60D in the grip state holds the loop in the holder H3. Next, the control unit 38 moves the holder H3 to the lower limit holder position (FIG. 12(G)). FIG. 20(A) corresponds to FIG. 12(G).
After the state in FIG. 12(G) is achieved, the control unit 38 moves the holder H2 to the lower limit holder position (FIG. 12(H)). FIG. 20(B) corresponds to FIG. 12(H). At the time of shifting from the state in FIG. 12(G) to the state in FIG. 12(H), the control unit 38 arranges the routed portion 62 to extend between the holder block B2 and the holder block B3 as illustrated in FIG. 20(B). The control unit 38 controls the catch drive mechanism, and if necessary, uses the holder block 6 and the needle 4 so as to shift the state of the routed portion 62 from the state of being extended between the holder block B1 and the holder block B2 to the state of being extended between the holder block B2 and the holder block B3. Although not described in detail below, the state of the routed portion 62 is appropriately changed by the control unit 38 as necessary.
Through the flow from the state in FIG. 12(B) to the state in FIG. 12(H), the stitch on the second row in the first layer is knitted. The loop on the second row in the first layer is held by the lower holding part 60D of the holder H2. Furthermore, a new loop (loop in the third row) formed by knitting the stitch on the second row is held by the holder H3. As will be apparent later, the holder H2 continues to hold the loop on the second row in the first-layer knitted fabric even after the knitting of the first-layer knitted fabric is completed, and further continues to hold the loop until the knitting of the stitch on the second row in the second layer is completed.
After the state of the knitting mechanism 7 becomes the state in FIG. 12(H), the control unit 38 controls each section of the knitting mechanism 7 to perform the same operation as when shifting from the state in FIG. 12(A) to the state in FIG. 12(H) to shift the state of the knitting mechanism 7 in order of FIG. 12(I)→FIG. 12(J)→FIG. 12(K)→FIG. 13(A)→FIG. 13(B)→FIG. 13(C). FIG. 21(A) corresponds to FIG. 13(C). Stitches are knitted on the third row in the first layer by a series of operations for shifting from the state in FIG. 12(I) to the state in FIG. 13(C). In FIG. 13(C), the lower holding part 60D of the holder H3 holds a loop on the third row in the first layer, and the holder H4 holds a new loop on the fourth row formed by knitting the stitch on the third row. The holder H3 continues to hold the loop on the third row in the first-layer knitted fabric even after the knitting of the first-layer knitted fabric is completed, and further continues to hold the loop until the knitting of the stitch on the third row in the second layer is completed.
After the state of the knitting mechanism 7 becomes the state in FIG. 13(C), the control unit 38 controls the knitting mechanism 7 to perform the operation to shift from the state in FIG. 13(D) to the state in FIG. 14(I). This operation is to knit stitches on the fourth row in the first layer, completing the knitting of the first-layer knitted fabric, and turning back the direction in the column direction of the knitted fabric to start knitting a second-layer knitted fabric. More specifically, the control unit 38 elevates the holder H4 to the upper limit holder position (FIG. 13(D)). Next, the control unit 38 knits a new stitch on the fourth row in the first layer by passing the thread 3 through the loop held by the holder H4, using the needle 4A (FIGS. 13(E) and 13(F)).
Next, the control unit 38 transfers the loop held by the needle 4A to the holder H5 (FIG. 13(G)). Next, the control unit 38 moves the needle 4A forward (FIG. 13(H)). Next, the control unit 38 controls the holder H5 to perform the first revolving operation (FIG. 13(I)) to achieve the state that the lower holding part 60D of the holder H5 holds the loop (FIG. 13(I)). Next, the control unit 38 elevates the holder H5 to the upper limit holder position and also lowers the holder H4 to a predetermined position (FIG. 13(J)). FIG. 21(B) corresponds to FIG. 13(J).
Next, the control unit 38 moves the needle 4A backward until the hooks 14 of the needle 4A reach below the holder H4, so as to transfer the loop held by the holder H4 to the needle 4A (FIG. 14(A)). FIG. 22(A) corresponds to FIG. 14(A). The transfer of the loop from the holder H4 to the needle 4A is performed as follows. In other words, the control unit 38 brings the needle 4A into the non-gap state, and passes the hooks 14 of the needle 4A through the loop lifted by the holder H4. As a result, the hooks 14 of the needle 4A pass through the loop held by the holder H4, and the lower holding part 60D of the holder H4 holding the loop is located above the hooks 14. From this state, the control unit 38 brings the needle 4A into the gap state to let the lower holding part 60D holding the loop enter between the pair of hooks 14. Next, the control unit 38 changes the lower holding part 60D of the holder H4 to the open state to release the loop held by the lower holding part 60D. Then, the loop held by the lower holding part 60D is pulled by the holder H3 and moves downward to be retained by the pair of hooks 14. As described above, the loop is transferred from the holder H4 to the needle 4A.
After the loop is transferred to the needle 4A, the control unit 38 elevates the holder H4 to the upper limit holder position (FIG. 14(B)). Next, the control unit 38 moves the needle 4A forward until the hooks 14 of the needle 4A is located forward of the holder H5 (FIG. 14(C)). Next, the control unit 38 lowers the holder H5 to a predetermined position (FIG. 14(D)), moves the needle 4B forward, and transfers the loop held by the lower holding part 60D of the holder H5 to the needle 4B (FIG. 14(E)). Next, the control unit 38 elevates the holder H5 to the upper limit holder position (FIG. 14(F)). Next, the control unit 38 moves the needle 4A and the needle 4B backward such that the hooks 14 of the needle 4A are located below the holder H4 and the hooks 14 of the needle 4B are located above the holder H3 (FIG. 14(G)). FIG. 22(B) corresponds to FIG. 14(G). In FIG. 22(B), the needle placement plate 12 of the second needle unit 9 is omitted for ease of viewing of the drawing.
Next, the control unit 38 lowers the holder H4 to transfer the loop retained by the needle 4A to the holder H4 to achieve the state that the lower holding part 60D in the grip state of the holder H4 holds the loop on the fourth row in the first layer (FIG. 14(H)). Next, the control unit 38 lowers the holder H4 to the lower limit holder position while the lower holding part 60D in the grip state holds the loop (FIG. 14(I)). The knitting of the first-layer knitted fabric is completed in the state in FIG. 14(I). As illustrated in FIG. 14(I), in the state in FIG. 14(I), the loop on the second row in the first layer is held by the lower holding part 60D of the holder H2 for the second row, the loop on the third row in the first layer is held by the lower holding part 60D of the holder H3 for the third row, and the loop on the fourth row in the first layer is held by the lower holding part 60D of the holder H4 for the fourth row. In addition, as described above, the cast-on loop (loop on the first row) is held by the lower holding part 60D of the holder H1 for the first row.
After the state in FIG. 14(I) is achieved, the control unit 38 elevates the holder H3 for a predetermined amount, transfers the loop retained by the needle 4B to the upper holding part 60U in the open state of the holder H3 (FIG. 14(J)), and moves the needle 4B backward (FIG. 15(A)). FIG. 23(A) corresponds to FIG. 15(A). In the state in FIG. 15(A), the holder H3 holds the loop on the third row in the first layer by the lower holding part 60D in the grip state, and holds the loop on the third row in the second layer by the upper holding part 60U in the open state. The loop on the third row in the second layer is a loop formed by knitting a stitch on the fourth row in the second layer (corresponding to a row immediately preceding the third row in the second layer). The “loop on the third row in the first layer” corresponds to a loop at a position corresponding to the position of the “loop on the third row in the second layer”. The position of a loop in one layer corresponds to the position of a loop in a next layer above the one layer means that the loops are in such a positional relationship that the thread 3 is simultaneously passed through when knitting a stitch in the next-layer knitted fabric.
Next, the control unit 38 elevates the holder H3 to the upper limit holder position (FIG. 15(B)). As described above, the upper limit holder position is a position exceeding the positions of the needle 4A and the needle 4B upward in the top-bottom direction. FIG. 23(B) corresponds to FIG. 15(B). Next, the control unit 38 brings the needle 4B into the non-gap state. The control unit 38 moves the needle 4B in the non-gap state forward while making the needle 4B pass through two loops held by the holder H3 (two loops lifted by the holder H3) located at the upper limit holder position. Then, the control unit 38 controls the catch drive mechanism to adjust the state of the routed portion 62, and the thread 3 is retained by the hooks 14 of the needle 4B (FIG. 15(C)).
Next, the control unit 38 moves the needle 4B backward while making the needle 4B pass through both of the two loops held by the holder H3. The control unit 38 moves the needle 4B backward until the hooks 14 of the needle 4B reaches above the holder H2 (FIG. 15(D)). FIG. 24(A) corresponds to FIG. 15(D). In this way, as shown in FIG. 15(D), the thread 3 is passed through the loop on the third row in the second layer (loop held by the upper holding part 60U of the holder H3) to knit a new stitch on the third row in the second layer, and also form a new loop (loop retained by the needle 4B). Furthermore, the loop newly formed by knitting the loop on the third row (loop retained by the needle 4B) is also passed through the loop of the stitch on the third row in the first layer.
Next, the control unit 38 controls the holder state changer 44 corresponding to the holder H3 to perform the second revolving operation, and shifts the state of the lower holding part 60D of the holder H3 from the grip state to the open state (FIG. 15(E)). Then, the loop held by the lower holding part 60D of the holder H3 is released to drop the loop of the stitch on the third row in the first layer. Thus, the holder H3 continues to hold the loop on the third row in the first layer even after the knitting of the stitch on the third row in the first layer, and the holder H3 releases the loop held after the knitting of the stitch on the third row in the second layer, which is one layer above the first layer, is completed.
Next, the control unit 38 controls the holder state changer 44 corresponding to the holder H3 to perform the third revolving operation and bring the holder H3 into a state that the lower holding part 60D is in the grip state to hold the loop on the third row in the second layer (FIG. 15(F)). Then, the control unit 38 lowers the holder H3 to the lower limit holder position (FIG. 15(G)). FIG. 24(B) corresponds to FIG. 15(F). FIG. 25(A) corresponds to FIG. 15(G). However, FIG. 25(A) illustrates the knitting mechanism 7 in the state in FIG. 15(G) when seen from the lower side to the upper side.
FIGS. 29(A) and (B) schematically show, in a manner suitable for description, a state in which the stitches on the third row in the second layer are knitted by a series of operations to shift the state from that in FIG. 14(I) to that in FIG. 15(G). FIG. 29(A) illustrates a part of the second row, the third row, and the fourth row in the first-layer knitted fabric, and also loops R2-3 oriented backwardly (new loops formed by knitting the stitches on the fourth row in the second layer) formed by passing the thread 3 through the loops on the fourth row in the first knitted layer. In the states shown in FIGS. 14(J) to 15(D), the loops R2-3 are held by the upper holding part 60U of the holder H3, and loops R1-3 of the stitches on the third row in the first layer are held by the lower holding part 60D of the holder H3. The thread 3 is passed through both the loops R2-3 and the loops R1-3 by the operation of shifting from the state in FIG. 15(B) to the state in FIG. 15(D). Thus, as shown in FIG. 29(B), new stitches are knitted on the third row in the second layer, and new loops R2-2 that pass through both the loops R2-3 and the loops R1-3 are formed. Therefore, the loops R2-3 in the second layer and the loops R1-3 in the first layer are inseparably connected.
FIG. 15(G) illustrates the state that the lower holding part 60D of the holder H3 holds the loop on the third row in the second layer. The holder H3 continues to hold the loop on the third row in the second-layer knitted fabric even after the knitting of the second-layer knitted fabric is completed. The holder H3 continues to hold the loop until the knitting of the stitch on the third row in the third layer is completed.
After the state in FIG. 15(G) is achieved, the control unit 38 controls each section of the knitting mechanism 7 to perform the same operation as when shifting from the state in FIG. 14(J) to the state in FIG. 15(G), and shifts the state of the knitting mechanism 7 in order of FIG. 15(H)→FIG. 15(I)→FIG. 15(J)→FIG. 16(A)→FIG. 16(B)→FIG. 16(C)→FIG. 16(D). More specifically, the control unit 38 elevates the holder H2 for the second row, and transfers the loop retained by the needle 4B (loop newly formed by knitting the stitch on the third row, which is a row immediately preceding the second row in the second layer) to the upper holding part 60U of the holder H2 (FIG. 15(H)). The control unit 38 moves the holder H2 to the upper limit holder position (FIG. 15(I)), and passes the thread 3 through the two loops lifted by the holder H2, using the needle 4B (FIG. 15(I), FIG. 15(J), and FIG. 16(A)). The control unit 38 releases the loop held by the holder H2 to drop the loop on the second row in the first layer (FIG. 16(B)). The control unit 38 causes the holder state changer 44 to perform the third revolving operation to bring the lower holding part 60D of the holder H2 into a state of holding the loop (loop on the second row in the second layer) (FIG. 16(C)). Then, the control unit 38 moves the holder H2 to the lower limit holder position (FIG. 16(D)). FIG. 25(B) corresponds to FIG. 16(D).
Through a series of operations from FIG. 15(H) to FIG. 16(D), a new stitch is knitted on the second row in the second layer, and also a new loop (loop retained by the needle 4B) is formed. This loop newly formed by knitting the stitch on the second row is in a state that the loop has passed through the loop on the second row in the first layer in addition to the loop on the immediately preceding row in the second layer. FIG. 16(D) illustrates the state that the holder H2 holds the loop on the second row in the second layer of the knitted fabric. The holder H2 continues to hold the loop on the second row in the second-layer knitted fabric even after the knitting of the second-layer knitted fabric is completed. The holder H2 further continues to hold the loop until the knitting of the stitch on the second row in the third layer is completed.
After the state in FIG. 16(D) is achieved, the control unit 38 controls the knitting mechanism 7 to perform the operation of shifting from the state in FIG. 16(E) to the state in FIG. 16(K). This operation corresponds to an operation of knitting the first row in the second-layer knitted fabric to complete the knitting of the second-layer knitted fabric, and turning back the direction in the column direction of the knitted fabric to start knitting the third-layer knitted fabric.
More specifically, the control unit 38 elevates the holder H1 and transfers the loop from the needle 4B to the upper holding part 60U of the holder H1 (FIG. 16(E)). As described above, the lower holding part 60D of the holder H1 actually holds the cast-on loop in the first layer. Next, the control unit 38 elevates the holder H1 to the upper limit holder position (FIG. 16(F)). Next, the control unit 38 forms a new loop by passing the thread 3, using the needle 4A, through the loop held by the holder H2 and lifted by the holder H1 (FIGS. 16(G) and 16(H)). At this point, the control unit 38 achieves a state in which the hook 14 of the needle 4A on which the loop is retained is positioned above the holder H2. The control unit 38 shifts the lower holding part 60D of the holder H1 to the open state to drop the loop held by the lower holding part 60D of the holder H1 (FIG. 16(I)). Next, the control unit 38 controls the holder state changer corresponding to the holder H1 to perform the first revolving operation to bring the lower holding part 60D of the holder H1 into a state of holding the loop (FIG. 16(J)), and moves the holder H1 to the lower limit holder position (FIG. 16(K)). Thereafter, a process similar to the operation of shifting from the state in FIG. 14(I) to the state in FIG. 16(D) is performed to knit the third-layer knitted fabric.
FIG. 29(C) shows a state in which a process of knitting the stitch in the second layer is performed after FIG. 29(B) and the stitches up to the fourth to first rows in the second layer are knitted. FIG. 29(D) shows a state in which a process of knitting the stitches in the third layer is further performed and the stitches are knitted on the first row and the second row in the third layer. As shown in FIG. 29(C), the stitch on the second row in the second layer is knitted by passing the thread 3 through both the loop R2-2 formed when knitting the stitch on the third row in the second layer (a row immediately preceding the second row in the second layer) and the loop R1-2 on the second row in the first layer. As a result, the loop R2-2 and the loop R1-2 are inseparably connected. At the start of knitting the third-layer knitted fabric, each of new loops formed by knitting the second-layer knitted fabric is held by the holder 16 for the corresponding row.
As shown in FIG. 29(D), in the third layer, the thread 3 is first passed through the loop R2-1 to form a stitch on the first row in the third layer, and also new loop R3-2 is formed. A stitch on the second row in the third layer is knitted by passing the thread 3 through the loops R3-2 formed by knitting of the stitch on the first row in the third layer (a row immediately preceding the second row in the third layer) and the loop R2-2 on the second row in the second layer. The stitch is knitted by passing the thread 3 (loop) through the loop R2-2 held by the lower holding part 60D of the holder H2 on the second row and the loop R3-2 held by the upper holding part 60U of the holder H2. As a result, the loops R2-2 and the loops R3-2 are inseparably connected. In the third layer, the stitches are knitted stepwise in a direction from the first row to the fifth row. Therefore, for example, in the first layer, a row immediately preceding the second row is the first row, and the row immediately preceding the fifth row is the fourth row.
As described above, in the present embodiment, the knitting mechanism 7 continues to retain loops formed at the time of knitting the (N−1)th-layer knitted fabric even after the completion of the knitting of the (N−1)th-layer knitted fabric. When the knitting mechanism 7 knits stitches in the Nth layer of the knitted fabric, the knitting mechanism 7 retains loops already formed in the Nth layer, and knits each stitch by passing the thread through the retained loop already formed in the Nth layer, and the loop at a position corresponding to the position of the loop already formed in the Nth layer in the loops retained in the (N−1)th layer. Retention of the loop at the corresponding position is released after the stitch is knitted. On the other hand, the knitting mechanism 7 continues to retain the loops already formed in the Nth layer even after the knitting of the Nth-layer knitted fabric is completed.
According to this configuration, when knitting the stitch in the Nth layer, the stitch is formed by passing the thread 3 through both the loop formed at the corresponding position in the (N−1)th layer and the loop already formed in the Nth layer. Therefore, the knitted product 2 formed of a plurality of layers of knitted fabric, in which two of knitted fabrics that are adjacent in the top-bottom direction are joined by connecting loops at mutually corresponding positions, can be knitted. The knitted product 2 knitted as described above is a new mode of knitted product 2 having a solid three-dimensional shape configured with a plurality of layers of knitted fabric. The present embodiment can provide the knitting mechanism 7 capable of knitting the knitted product 2 in this new mode, and a knitting method using the knitting mechanism 7.
The knitting mechanism 7 according to the present embodiment has the following structural features. Specifically, the knitting mechanism 7 includes a plurality of holders 16 arranged in a plurality of rows in the column direction. Each of the holders 16 includes two independent holding parts 60 capable of holding and releasing the loop. The knitting mechanism 7 continues to retain a plurality of loops of stitches aligned in the plurality of rows in the column direction in the (N−1)th layer by one holding parts 60 of the plurality of holders 16 even after the knitting the (N−1)th-layer knitted fabric is completed. To knit stitches on a predetermined row at knitting the Nth-layer knitted fabric, the knitting mechanism 7 retains loops formed on a row immediately preceding the predetermined row in the Nth layer by the other holding parts 60 of the holders 16 for the predetermined row, and knits stitches by passing the thread 3 through both the retained loops in the Nth layer and the loops in the (N−1)th layer held by the one holding parts 60 of the holders 16 for the predetermined row. After knitting the stitches, the other holding parts 60 continues to hold the loops in the Nth layer even after the knitting of the Nth-layer knitted fabric is completed. On the other hand, the one holding parts 60 release the loops in the (N−1)th layer.
More specifically, the two holding parts 60 of the holder 16 are arranged at symmetrical positions about a symmetric point, and the holder 16 is revolvable about the symmetric point while retaining the state in which the two holding parts 60 are located at positions symmetrical about the symmetric point. The knitting mechanism 7 continues to retain the plurality of loops aligned in the plurality of rows in the column direction in the (N−1)th layer by the holding parts 60 arranged on the lower side of the symmetric point of the plurality of holders 16 even after the knitting of the (N−1)th-layer knitted fabric is completed. To knit stitches on a predetermined row at the time of knitting the Nth-layer knitted fabric, the knitting mechanism 7 retains the loops formed on the row immediately preceding the predetermined row in the Nth layer by the holding parts 60 of the holders 16 for the predetermined row, which is arranged on the upper side of the symmetric point, and knits stitches by passing new loops through both the loops retained in the Nth layer and the loops in the (N−1)th layer held by the holding parts 60 on the lower side of the symmetric point of the holders 16 for the predetermined row. After knitting the stitches, the holding parts 60 on the lower side release the loops in the (N−1)th layer. While the holding parts 60 on the upper side continue to hold the loops in the Nth layer, the knitting mechanism 7 makes the holder 16 revolve about the symmetric point to locate the holding parts 60 holding the loops in the Nth layer on the lower side of the symmetric point.
According to this configuration, to knit the Nth-layer knitted fabric, the holders 16 for each row can be used to knit stitches on each row by passing the thread 3 through both the loops in the Nth layer and the loops in the (N−1)th layer. In particular, to knit stitches on the predetermined row in the Nth layer, one holder 16 for the predetermined row holds two loops through which the thread 3 is to be passed. Thus, the structure is simplified as compared with the case of holding two loops using a plurality of different holders.
In the present embodiment, the knitting mechanism 7 includes the needle 4 that can retain a loop. The holding part 60 of the holder 16 can receive a loop retained by the needle 4. To knit the Nth-layer knitted fabric, a stitch is knitted by passing the needle 4 retaining the loop through both the loop in the Nth layer held by the other holding part 60 of the holder 16 for a predetermined row and the loop in the (N−1)th layer held by the one holding part 60 of the holder 16 for the predetermined row. The other holding part 60 of the holder 16 for a row next to the predetermined row receives and holds the loop retained by the needle 4. The needle 4 retaining the loop is passed through both the loop in the Nth layer held by the other holding part 60 of the holder 16 for the row next to the predetermined row and the loop in the (N−1)th layer held by the one holding part 60. The knitting mechanism 7 forms stitches stepwise in the column direction by repeating these operations of knitting stitches. More specifically, to knit the Nth-layer knitted fabric, a stitch is knitted by passing the needle 4 retaining the loop through both the loop in the Nth layer held by the holding part 60 on the upper side of the symmetric point of the holder 16 for a predetermined row and the loop in the (N−1)th layer held by the holding part 60 on the lower side of the symmetric point of the holder 16 for the predetermined row. The holding part 60 on the upper side of the symmetric point of the holder 16 for a row next to the predetermined row receives and holds the loop retained by the needle 4. The needle 4 retaining the loop is passed through both the loop in the Nth layer held by the holding part 60 on the upper side of the holder 16 for the row next to the predetermined row and the loop in the (N−1)th layer held by the holding part 60 on the lower side. The knitting mechanism 7 forms stitches stepwise in the column direction by repeating these operations of knitting stitches.
According to this configuration, stitches in which the thread 3 is passed through both the loops in the N layer and the loops in the (N−1)th layer can be successively formed in the column direction using the structural feature of having the holders 16 for the plurality of rows in the column direction.
Still more, in the present embodiment, the needle 4 is movable in the horizontal direction intersecting the vertical direction while retaining the position in the vertical direction. Each of the holders 16 is movable in the vertical direction across a position of the needle 4 in the vertical direction. To knit the Nth-layer knitted fabric, the knitting mechanism 7 elevates, above the vertical position of the needle 4, the holder 16 for a predetermined row that holds the loop in the Nth layer by the other holding part 60 and holds the loop in the (N−1)th layer by the one holding part 60. To form a stitch, the knitting mechanism 7 horizontally moves the needle 4 retaining the loop so as to pass the needle 4 through the two loops lifted by the holder 16 for the predetermined row. More specifically, to knit the Nth-layer knitted fabric, the knitting mechanism 7 knits a stitch by elevating, above the vertical position of the needle, the holder 16 for a predetermined row that holds the loop in the Nth layer by the holding part 60 on the upper side of the symmetric point and holds the loop in the (N−1)th layer by the holding part 60 on the lower side of the symmetric point, and horizontally moving the needle retaining the loop so as to pass the needle through the two loops lifted by the holder 16 for the predetermined row.
According to this configuration, the holder 16 is moved in a specific direction, which is the vertical direction, and the needle 4 is moved in a specific direction, which is the horizontal direction, so that the stitches in which the thread 3 is passed through both the loops in the N layer and the loops in the (N−1)th layer can be successively formed in the column direction. Thus, the structure and the operation can be simplified.
Still more, in the present embodiment, to knit the Nth-layer knitted fabric, the knitting mechanism 7 elevates, above the vertical position of the needle, the holder 16 for a predetermined row that holds the loop in the Nth layer by the other holding part 60 and holds the loop in the (N−1)th layer by the one holding part 60. The knitting mechanism 7 forms stitches by horizontally moving the needle retaining the loop such that the needle passes through the two loops lifted by the holder 16 for the predetermined row and the portion retaining the loop reaches the position over the holder 16 for a row next to the predetermined row. The knitting mechanism 7 elevates the holder 16 for the row next to the predetermined row to receive the loop retained by the needle with the other holding part 60. More specifically, to knit the Nth-layer knitted fabric, the knitting mechanism 7 elevates, above the vertical position of the needle, the holder 16 for the predetermined row that holds the loop in the Nth layer by the holding part 60 on the upper side of the symmetric point and holds the loop in the (N−1)th layer by the holding part 60 on the lower side of the symmetric point. The knitting mechanism 7 forms stitches by horizontally moving the needle retaining the loop such that the needle passes through the two loops lifted by the holder 16 for the predetermined row and the portion retaining the loop reaches the position over the holder 16 for a row next to the predetermined row. The knitting mechanism 7 elevates the holder 16 for the row next to the predetermined row to receive the loop retained by the needle with the holding part 60 on the upper side of the symmetric point.
According to this configuration, the holders 16 are aligned in a plurality of rows in the column direction and move in the vertical direction and the needle 4 moves in the horizontal direction, so that stitches in which the thread 3 is passed through both the loops in the Nth layer and the loops in the (N−1)th layer can be successively formed. Thus, the structure and the operation can be simplified.
Furthermore, in the present embodiment, the holding part 60 receives the loop from the needle 4 by gripping the loop retained by the needle 4. The needle 4 has a pair of forked hooks 14 for retaining the loop. The loop is laid and retained across the pair of hooks 14, and the needle 4 can be shifted to the gap state in which a gap is formed between the hooks 14 to allow the holding part 60 gripping the loop to enter. When the holding part 60 of the holder 16 receives the loop retained by the needle 4, the knitting mechanism 7 brings the needle 4 into the gap state and elevates the holder 16 to let the portion of the holding part 60 for gripping the loop enter the gap formed between the pair of hooks 14 of the needle 4, so as to grip the loop by the holding part 60.
According to this configuration, the holder 16 moves in the vertical direction and the needle 4 moves in the horizontal direction. Thus, the holding part 60 of the holder 16 can appropriately receive the loop.
<Modified Example of First Embodiment>
Next, a modified example of the first embodiment will be described.
In the above embodiment, the number of column groups is five, and the number of rows provided with the holders 16 is five. However, the number of column groups (when the number of column groups changes, the number of needles 4 also changes) and the number of rows are not limited to those exemplified in the above embodiment.
Still more, the structure of the needle 4 is not limited to the shape exemplified in the present embodiment. FIG. 30 is a perspective view of a needle 4′ that is another example of the needle 4. In FIG. 30, a needle extender 5′ has a function similar to the needle extender 5, the hook 14′ has a function similar to the hook 14, and the band 15′ has a function similar to the band 15. As illustrated in FIG. 30, the needle 4′ is provided with an intervening member 70 between a pair of needle extenders 5′ to secure a certain distance between the pair of needle extenders 5′. The intervening member 70 extends substantially the half of the entire length of the pair of needle extenders 5′ on the opposite side of the hook 14′. The band 15′ is provided to protrude from the intervening member 70. The structure of the needle 4 is not limited to that described using FIG. 3, and may have the structure illustrated in FIG. 30.
Still more, the mechanism of the operation of the knitting mechanism 7 and the structure of each component are not limited to those exemplified in the above embodiment. For example, a mechanism to switch the state of the needle 4 between the pull-back state and the push-out state is not limited to that exemplified in the present embodiment. For example, a mechanism for moving the needle 4 in the front-back direction may be provided for each needle 4, and the mechanism may be controlled to switch each needle 4 between the pull-back state and the push-out state. Furthermore, for example, the mechanism to switch the state of the needle 4 between the gap state and the non-gap state is not limited to that exemplified in the present embodiment. For example, a mechanism for applying a force in a direction of closing the needle 4 may be provided for each needle 4, and this mechanism may be controlled to switch each needle 4 between the gap state and the non-gap state.
Still more, for example, the mechanism for elevating and lowering the holder block 6 is not limited to the mechanism using the pusher 35. For example, a mechanism that drives the motor to move the holder block 6 up and down in the vertical direction may be provided for each holder block 6, and the mechanism may be controlled to move each holder block 6 up and down. Further, for example, the structure of the holder 16 and the mechanism for changing the state of the holder 16 are not limited to those exemplified in the above embodiment. The holder 16 is sufficient as long as each of the two holding parts 60 can hold and release the thread 3 (loop), and also perform the following. Specifically, after the thread 3 is held by the holding part 60 located at the upper position, the position of the holding part 60 may be moved to a lower position while holding the thread 3. For example, each of the two holding parts 60 provided in one holder 16 may be provided with a motor to switch the state of each holding part 60 independently.

Second Embodiment

Next, a second embodiment will be described. In the following description of the second embodiment, the same components as those of the first embodiment are given the same reference signs as those in the first embodiment to omit detailed description thereof.
FIG. 31 is a perspective view illustrating an internal structure of a knitting machine 100 according to the present embodiment. FIG. 32(A) is a top view of the knitting machine 100, and FIG. 32(B) is a side view of the knitting machine 100 seen from the right side to the left side of the knitting machine 100. In FIGS. 31 and 32, illustration of some components is omitted. In the following description of the knitting machine 100, as indicated by a double-headed arrow in FIG. 31, a direction in which a paired needle 101 (described later) extends is defined as a front-back direction. One direction in the front-back direction is defined as front, and a direction opposite to the front is defined as back. Further, a direction in which a moving rod regulating member 102 (described later) is erected is defined as a top-bottom direction. The top-bottom direction corresponds to a vertical direction when the knitting machine 100 is used in a normal manner. A direction directed vertically upward in the top-bottom direction is defined as upward and a direction directed vertically downward in the top-bottom direction is defined as downward. Further, a direction orthogonal to the front-back direction on a horizontal plane perpendicular to the top-bottom direction is defined as a left-right direction. A right direction to the front in the left-right direction is defined as rightward, and a left direction to the front is defined as leftward.
As illustrated in FIGS. 31 and 32, the knitting machine 100 is equipped with a knitting mechanism 103. The knitting mechanism 103 includes a rear needle unit 104, a front needle unit 105 provided in front of the rear needle unit 104, a rear holder unit 106, and a front holder unit 107 provided in front of the rear holder unit 106.
As illustrated in FIG. 31, each of the rear needle unit 104 and the front needle unit 105 has five paired needles 101 (corresponding to a “needle member” in the claims) arranged at intervals in the left-right direction. FIG. 33(A) is a side view of the paired needle 101 with a paired latch 110 (described later) in an open state (described later). FIG. 33(B) is a side view of the paired needle 101 with the paired latch 110 in a closed state (described later). FIG. 33(C) is a top view of the paired needle 101. As shown in FIG. 33 (particularly FIG. 33(C)), the paired needle 101 includes two single needles 112 connected to both side surfaces of a quadrangular prism shaped intervening member 111 so as to overlap each other when viewed from the side.
Assuming that a side on which a single hook 113 (described later) is provided is a tip side (FIG. 33(A)) and the opposite side is a base side (FIG. 33(A)), the single needle 112 includes a single-needle base part 114 and a single-needle tip part 115, supported by the single-needle base part 114, on the tip side of the single-needle base part 114. The single-needle base part 114 is a sheet-like member extending in the front-back direction (see also FIG. 31). Hereinafter, focusing on the paired needle 101, a direction toward the tip in the front-back direction is referred to as a “tip direction”, and a direction toward the base is referred to as a “base direction”. A single pushing surface 116 (FIGS. 33(A) and 33(B)) is formed on a surface of the single-needle base part 114 facing the tip direction.
As illustrated in FIG. 33, the single hook 113 is formed at the tip of the single-needle tip part 115. The single hook 113 has a curved claw, and a retaining space capable of accommodating the thread is formed inside the claw. An inlet 117 (FIG. 33(A)) through which the thread 3 passes when the thread 3 enters the retaining space is formed at a portion corresponding to a tip of the claw of the single hook 113. The single-needle tip part 115 is provided with a single latch 118 that is revolvable about a revolution shaft and can shift a state between a closed state (FIG. 33(B)) of closing the inlet 117 and a closed state (FIG. 33(A)) of opening the inlet 117. Still more, in the single-needle tip part 115, a single recess 119 (FIGS. 33(A) and (B)) dented downward is formed in the base direction of the single latch 118.
A pair of single-needle base parts 114 of a pair of single needles 112 of one paired needle 101 configure a needle base part 120. A pair of single-needle tip parts 115 configure a needle tip part 121. A pair of single hooks 113 configure a paired hook 122 (corresponding to a “hook member” in the claims). A pair of single latches 118 configure the paired latch 110 (corresponding to a “latch” in the claims). A pair of single recesses 119 configure a paired recess 123. A pair of single pushing surfaces 116 configure a paired pushing surface 124 (corresponding to a “pushing surface” in the claims).
As illustrated in FIGS. 31 and 32, five paired needles 101 in the rear needle unit 104 are arranged such that their tip direction conforms to the front direction. The five paired needles 101 in the front needle unit 105 are arranged such that their tip direction conforms to the back direction. The five paired needles 101 in the rear needle unit 104 are synchronously movable in the front-back direction by a needle unit drive mechanism (not illustrated). The five paired needles 101 in the front needle unit 105 are synchronously movable in the front-back direction by the needle unit drive mechanism (not illustrated). In the present embodiment, the paired needles 101 of the rear needle unit 104 and the front needle unit 105 move synchronously in consideration of convenience of description, but the operation may not be synchronized, and the paired needles 101 may be operated one by one or in a plurality of numbers sequentially. Hereinafter, the five paired needles 101 in the rear needle unit 104, from right to left, are referred to as first rear paired needle BA1, a second rear paired needle BA2, and so on to a fifth rear paired needle BA5 (see FIG. 31). Further, the five paired needles 101 in the front needle unit 105, from right to left, are referred to as a first front paired needle FA1, a second front paired needle FA2, and so on to a fifth front paired needle FA5 (see FIG. 31).
As illustrated in FIGS. 31 and 32, the rear holder unit 106 includes a rear holder plate group 126 and a pair of moving rod regulating members 102. The rear holder plate group 126 includes ten holder plates 127 (corresponding to a “holder forming member” in the claims). Hereinafter, the ten holder plates 127 of the rear holder plate group 126, from right to left, are sequentially referred to as a first rear holder plate BH1, a second rear holder plate BH2, a third rear holder plate BH3, and so on to a tenth rear holder plate BH10 (See FIG. 35). FIG. 34 is a side view of the first rear holder plate BH1 seen from the right side to the left side. The first rear holder plate BH1 illustrated in FIG. 34 is in a state that two fixing members 125 (described later) are attached.
As illustrated in FIG. 34, the holder plate 127 (the first rear holder plate BH1 in FIG. 34) has a shape curved as a whole protruding forward from the upper end to the lower end as a whole when viewed from the side. The first rear holder plate BH1 includes an upper extending portion 128 that is curved downward toward the front side from an upper end, a lower extending portion 129 that is curved upward toward the front from a lower end, and a bulging portion 130 that is interposed between the upper extending portion 128 and the lower extending portion 129 and bulges forward.
The bulging portion 130 of the first rear holder plate BH1 has seven recesses 131 that are open on the front side and recessed such that the recess gradually narrows toward the rear side. Note that the shape of the recess 131 is merely an example, and may be configured to extend with a substantially constant width without gradually narrowing. Hereinafter, the seven recesses 131 formed in the holder plate 127, from the bottom, are sequentially referred to as a first-row recess HK1, a second-row recess HK2, and so on to a seventh-row recess HK7. A holding part 132 (corresponding to a “holding portion” in the claims) is formed above the opening of the recess 131. As illustrated in FIG. 34, the holding part 132 of the first rear holder plate BH1 has a hook-shaped member, and an inlet 133 is formed at a position corresponding to a tip of the hook-shaped member. A retaining space is formed inside the hook-shaped member.
The thread 3 can enter the retaining space through the inlet 133. In order for the thread 3 to enter the retaining space, the thread 3 first needs to enter inside the recess 131, move relatively forward from the back side of the inlet 133 with respect to the inlet 133, and enter the retaining space through the inlet 133. Hereinafter, the seven holding parts 132 formed on the holder plate 127, from the bottom, are referred to as a first-row holding part HJ1, second-row holding part HJ2, and so on to a seventh-row holding part HJ7. As will be apparent later, each of the holding parts 132 of the holder plate 127 can hold a plurality of loops formed in the column direction in one layer.
As illustrated in FIG. 34, a first plate through hole 135 and a second plate through hole 136 are formed at intervals in order toward the front in the upper extending portion 128, and a third plate through hole 137 and a fourth plate through hole 138 are formed at intervals in order toward the back side in the lower extending portion 129. Each of the first plate through hole 135, the second plate through hole 136, the third plate through hole 137, and the fourth plate through hole 138 (hereinafter, when these are not distinguished, they are simply referred to as a “plate through hole”) is a through hole penetrating the first rear holder plate BH1 (holder plate 127). The holder plate 127 other than the first rear holder plate BH1 has the same structure as the first rear holder plate BH1.
As illustrated in FIG. 34, a fixing member 125 is attached to a position corresponding to the second plate through hole 136 and a position corresponding to the fourth plate through hole 138 on the right surface of the first rear holder plate BH1. A through hole communicating with a corresponding plate through hole is formed in the fixing member 125.
FIG. 35(A) is a perspective view of the rear holder plate group 126 in a pair separated state (described later) and related members, and FIG. 35(B) is a perspective view of the rear holder plate group 126 in a pair proximity state (described later) and related members. In the rear holder plate group 126, two plates are paired from right to left to form plate pairs 140. More specifically, the first rear holder plate BH1 and the second rear holder plate BH2 are paired to configure a first rear plate pair PB1, the third rear holder plate BH3 and the fourth rear holder plate BH4 are paired to configure a second rear plate pair PB2, the fifth rear holder plate BH5 and the sixth rear holder plate BH6 are paired to configure a third rear plate pair PB3, the seventh rear holder plate BH77 and the eighth rear holder plate BH8 are paired to configure a fourth rear plate pair PB4, the ninth rear holder plate BH9 and the tenth rear holder plate BH10 are paired to configure a fifth rear plate pair PB5.
The holder plate 127 located on the right side of each of the plate pairs 140 in the rear holder plate group 126 is provided with the fixing members 125 on the right surface, corresponding to the second plate through hole 136 and the fourth plate through hole 138. Still more, the holder plate 127 located on the left side of each of the plate pairs 140 in the rear holder plate group 126 is provided with the fixing members 125 on the left surface, corresponding to the first plate through hole 135 and the third plate through hole 137. As illustrated in FIGS. 31 and 35, a bar-like first moving rod 141 is inserted into the first plate through holes 135 of all the holder plates 127 in the rear holder plate group 126 and the fixing members 125 provided corresponding to the first plate through holes 135. Similarly, the second moving rod 142 is inserted into all the second plate through holes 136 and corresponding fixing members 125, the third moving rod 143 is inserted into all the third plate through holes 137 and corresponding fixing members 125, and the fourth moving rod 144 is inserted into all the fourth plate through holes 138 and corresponding fixing members 125. Hereinafter, when the first to fourth moving rods 141 to 144 are not distinguished, they are referred to as a “moving rod”.
Each of the fixing members 125 is fixed to the moving rod inserted therein. The first moving rod 141 and the third moving rod 143 are synchronously movable in the left-right direction by a moving rod drive mechanism (not illustrated). Similarly, the second moving rod 142 and the fourth moving rod 144 are synchronously movable in the left-right direction by the moving rod drive mechanism. Since each of the fixing members 125 is fixed to the moving rod inserted therein, when the first moving rod 141 and the third moving rod 143 synchronously move in the left-right direction, the holder plate 127 located on the left side of each of the plate pairs 140 also moves according to the movement of the moving rods. Similarly, when the second moving rod 142 and the fourth moving rod 144 synchronously move in the left-right direction, the holder plate 127 located on the right side of each of the plate pairs 140 also moves according to the movement of the moving rod. Although both the first moving rod 141 and the third moving rod 143 are configured to be moved, only one of the moving rods may be moved so as to move the corresponding holder plate 127. The same applies to the first moving rod 141 and the third moving rod 143.
The rear holder plate group 126 can take two states, i.e., the pair separated state (FIG. 35 (A)) and the pair proximity state (FIG. 35 (B)). As illustrated in FIG. 35 (A), the pair separated state is a state in which a certain gap or more is provided in each plate pair 140. In the present embodiment, the pair separated state is, for two adjacent plate pairs 140, when the fixing member 125 of the holder plate 127 on the left side in the right plate pair 140 is in contact with or is in proximity with the right surface of the holder plate 127 on the right side of the left plate pair 140. In a side view, the fixing member 125 corresponding to the first plate through hole 135 and the fixing member 125 corresponding to the second plate through hole 136 are designed so as not to overlap each other. Also in the side view, the fixing member 125 corresponding to the third plate through hole 137 and the fixing member 125 corresponding to the fourth plate through hole 138 are designed so as not to overlap each other. Note that, in the pair separated state, any form of the fixing member 125 may be used as long as a gap in the plate pair 140 can be secured to such an extent that the paired needle 101 can pass therethrough. For example, the fixing members may overlap when viewed from the side. When the rear holder plate group 126 is in the pair separated state, the paired needles 101 in the rear needle unit 104 and the paired needles 101 in the front needle unit 105 are located at positions corresponding to the gap formed in each of plate pairs 140 when the rear holder plate group 126 is viewed from the front side toward the back.
As illustrated in FIG. 35 (B), the pair proximity state is a state in which the two holder plates 127 of each of the plate pairs 140 are in contact with or in proximity to each other.
In one plate pair 140, a paired holding part 146 is configured with a pair of holding parts 132 provided in the two holder plates 127. Hereinafter, as illustrated in FIGS. 35 and 36, seven paired holding part 146 in one plate pair 140 are referred to as, in order from the bottom, a first-row paired holding part TH1, a second-row paired holding part TH2, a third-row paired holding part TH3, a fourth-row paired holding part TH4, a fifth-row paired holding part TH5, a sixth-row paired holding part TH6, and a seventh-row paired holding part TH7. As will be apparent later, in the pair separated state, the paired holding part 146 holds a loop in a state that the inside of the loop is enlarged. In addition, in one plate pair 140, paired recess 148 is configured with a pair of recesses 131 provided in the two holder plates 127. Hereinafter, as illustrated in FIG. 35, seven paired recesses 148 in one plate pair 140 are referred to as, in order from the bottom, a first-row paired recess TK1, a second-row paired recess TK2, a third-row paired recess TK3, a fourth-row paired recess TK4, a fifth-row paired recess TK5, a sixth-row paired recess TK6, and a seventh-row paired recess TK7.
As illustrated in FIGS. 31 and 32, in the rear holder unit 106, a pair of moving rod regulating members 102 are provided on the right side and the left side of the rear holder plate group 126. Four moving rods provided corresponding to the rear holder plate group 126 are inserted into each of the moving rod regulating notch 147 formed in the pair of moving rod regulating members 102. The moving rod regulating notch 147 in the moving rod regulating member 102 on the right side is curved protruding forward, and is formed along a circumference of a virtual circle. The same applies to the moving rod regulating notch 147 in the moving rod regulating member 102 on the left side. Each of the moving rods can synchronously move and stop along the moving rod regulating notch 147 while retaining a state of extending in the left-right direction and also retaining a relative positional relationship of the moving rods by the moving rod drive mechanism. As each moving rod moves along the moving rod regulating notch 147, respective holder plates 127 of the rear holder plate group 126 also move accordingly.
The rear holder unit 106 (the rear holder plate group 126 and the pair of moving rod regulating members 102) have been described above, and the front holder unit 107 has the same structure as the rear holder unit 106 except that the components are disposed in a direction opposite to the rear holder unit 106 in the front-back direction. Hereinafter, the ten holder plates 127 of the front holder unit 107 are referred to as a front holder plate group 145 (FIGS. 31 and 32). The ten holder plates 127 of the front holder plate group 145 are sequentially referred to as, from right to left, a first front holder plate FH1, a second front holder plate FH2, and so on to a tenth front holder plate FH10 (FIG. 32(A)). In addition, the plate pair 140 includes, from right to left, a first front plate pair PF1, a second front plate pair PF2, a third front plate pair PF3, a fourth front plate pair PF4, and a fifth front plate pair PF5. Further, components and portions of the front holder unit 107 having the same functions as those of the rear holder unit 106 are given the same reference signs unless otherwise specified.
The holder plate 127 of the rear holder plate group 126 and the holder plate 127 of the front holder plate group 145 are configured such that an arbitrary holding part 132 of one holder plate 127 and an arbitrary holding part 132 of the other holder plate 127 can face each other in the front-back direction by changing mutual postures. For example, as illustrated in FIG. 50(B) to be used later, the seventh-row holding part HJ7 of the holder plate 127 in the rear holder plate group 126 and the first-row holding part HJ1 of the holder plate 127 in the front holder plate group 145 may face each other. As illustrated in FIG. 65(A), the first-row holding part HJ1 of the holder plate 127 in the rear holder plate group 126 and the seventh-row holding part HJ7 of the holder plate 127 in the front holder plate group 145 may also face each other.
The knitting machine 100 includes a control unit 150 (FIG. 31). The control unit 150 controls various drive mechanisms (including the needle unit drive mechanism and the moving rod drive mechanism described above) to operate the knitting mechanism 103. In particular, the knitting machine 100 includes a routing mechanism (not illustrated), and the control unit 150 performs routing of the thread 3 by controlling the routing mechanism.
Next will be described a specific example of the operation for knitting the knitted product 2, using the knitting mechanism 103 of the knitting machine 100 that has the above structural features. First, how the knitted product 2 is knitted by the operation of the knitting mechanism 103 will be described, using FIG. 36. In the present embodiment, a method of counting the number of rows in the knitted fabric is different from that of the first embodiment in order to simplify the description. Specifically, in the present embodiment, in a certain layer, a loop formed on the first row is defined as a loop on the first row, and a stitch on the first row is knitted by passing the thread 3 through this loop on the first row. The number of rows sequentially increases, such as the second row and the third row, according to the knitting of the knitted fabric in the column direction (=so-called wale direction).
The principle of knitting the knitted product 2 by the knitting machine 100 according to the present embodiment is similar to that of the knitting machine 1 according to the first embodiment. In other words, as shown in FIG. 36(A), the knitting mechanism 103 first knits a first-layer knitted fabric. The first-layer knitted fabric is knitted by passing the thread 3 through the loop on the first row to knit a stitch on the first row, and then stitches are sequentially knitted up to the sixth row. In the process, loops on the second row to the seventh row are sequentially formed to knit. More specifically, first by the knitting mechanism 103, the thread 3 is passed through a loop on the first row in the first layer called a cast-on loop. Then, a stitch on the first row in the first layer is knitted and also a loop on the second row in the first layer is formed. In this way, stitches are knitted and loops are formed sequentially. When the thread 3 is passed through the loop on the sixth row in the first layer, a stitch on the sixth row in the first layer is knitted and also a loop on the seventh row in the first layer is formed. Even after knitting of the first-layer knitted fabric is completed, the knitting mechanism 103 (specifically, each holding part 132 of the rear holder plate group 126 in the present embodiment) retains each of the loops on the first to seventh rows in the first layer.
After knitting the first-layer knitted fabric, the knitting mechanism 103 sets the loop on the seventh row in the first layer as a loop on the first row in the second layer, as illustrated in FIG. 36(B). Then, the knitting mechanism 103 knits a stitch on the first row in the second layer by passing a new thread 3 through the loop on the first row in the second layer and also forms a loop on the second row in the second layer. Turning back from the first layer to the second layer, is different from turning back from the second layer and after (turning back from the second layer to the third layer, from the third layer to the fourth layer, and so on). The thread 3 is passed only through the loop in the current layer (=loop on the first row in the second layer) to knit the stitch on the first row, instead of passing the thread 3 through both the loop in the current layer (second layer) and the loop in a layer immediately preceding the current layer (first layer). This is because if the thread 3 is passed through both the loop on the first row in the second layer (=seventh row in the first layer) and the loop on the sixth row in the first layer, the loop on the first row in the second layer (=seventh row in the first layer) will be passed through the loop on the sixth row in the first layer together with the thread 3. This causes the thread to unravel.
As shown in FIG. 36(C), the knitting mechanism 103 then knits a stitch on the second row in the second layer and form a new loop on the third row in the second layer by passing the thread 3 through both the loop on the second row in the second layer and the retained loop on the sixth row in the first layer. In other words, when the knitting mechanism 103 knits the stitch on the second row in the second layer, the knitting mechanism 103 retains the loop already formed in the second layer (loop formed in the immediately preceding row) and passes the thread 3 through the loop retained and the loop on the sixth row in the first layer equivalent to “a loop at a position corresponding to a position of a loop already formed in the second layer in the loops retained in the first layer” to knit the stitch. After knitting the stitch, the knitting mechanism 103 continues to retain the loop in the second layer, and releases the loop retained in the first layer.
Thereafter, as shown in FIG. 36(C), the knitting mechanism 103 sequentially knits a new stitch and also forms a new loop by passing the thread 3 through both the loop already formed in the second layer and the corresponding loop in the first layer, so as to knit the second-layer knitted fabric. When knitting the third-layer knitted fabric, after knitting the second-layer knitted fabric, the knitting mechanism 103 releases the loop on the first row in the first layer (cast-on loop) that has been retained. Then, as illustrated in FIG. 36(D), the knitting mechanism 103 sets the loop on the seventh row in the second layer, which is the last row in the second layer (loop formed by knitting a stitch on the sixth row in the second layer) as a loop on the first row in the third layer. The knitting mechanism 103 passes the thread 3 through both the loop on the first row in the third layer and the retained loop on the sixth row in the second layer to knit a stitch on the first row in the third layer and also form a loop on the second row in the third layer. Thereafter, the knitting mechanism 103 sequentially knits a stitch and also form a new loop by passing the thread 3 through both the loop already formed in the third layer (second row, third row, and so on in the third layer) and the corresponding loop in the second layer (fifth row, fourth row, and so on in the second layer), so as to knit the third-layer knitted fabric. As described above, the knitting mechanism 103 knits the knitted product 2 including a plurality of layers of knitted fabric.
Next, the operation of the knitting mechanism 103 when knitting the knitted product 2 will be described in detail. FIGS. 37 to 63 illustrate the knitting mechanism 103 when knitting the knitted product 2. Time passes from FIG. 37 to FIG. 63. In each of FIGS. 37 to 63, (A) shows a perspective view of the knitting mechanism 103 (however, FIG. 50, (A1), (A2), and (B) illustrate a state of the knitting mechanism 103 seen from right to left. In each of FIG. 37 to 63, (A) (or (A1), (A2)) and (B) illustrate the knitted product 2 at the same timing. Note that, in each of FIGS. 37 to 63, illustration of a predetermined member may be omitted for ease of viewing of the drawing. In the following description, it is assumed that the control unit 150 controls a range of drive mechanisms to operate the knitting mechanism 103, and thus processes in the control unit 150 will not be particularly mentioned.
When knitting the knitted product 2, the knitting mechanism 103 is in the state in FIG. 37. In the state in FIG. 37, the rear holder plate group 126 is in the pair separated state. The thread 3 is set to the rear holder plate group 126. FIG. 64 is a schematic front view illustrating in a simplified manner the state that the thread 3 is set to the first-row recess HK1 and the first row holding part HJ1 in the rear holder plate group 126. In FIG. 64, the widths of the first-row recess HK1 and the widths of the first-row holding part HJ1 differ for the sake of easy viewing of the drawing.
As illustrated in FIGS. 37 and 64, in the state in FIG. 37, the thread 3 extends from the right side of the first-row recess HK1 of the first rear holder plate BH1 to the left side of the first-row recess HK1 of the tenth rear holder plate BH10 through all of the first-row recesses HK1 of the holder plates 127. Hereinafter, in the state in FIG. 37, a portion of the thread 3 passing through each of the first row recesses HK1 of the rear holder plate group 126 and extending in the left-right direction is referred to as a “rear first-row left-right extending portion 152”. The thread 3 is turned back on the left side of the first-row recess HK1 of the tenth rear holder plate BH10, wound around the first-row paired holding part TH1 (both the first-row holding part HJ1 of the tenth rear holder plate BH10 and the first-row holding part HJ1 of the ninth rear holder plate BH9) of the fifth rear plate pair PB5, and held as a loop (so-called cast-on loop) by the first-row paired holding part TH1. Referring to FIG. 36 (A), the loop held by the first-row paired holding part TH1 of the fifth rear plate pair PB5 corresponds to the leftmost loop on the first row in the first layer in FIG. 36 (A). After being wound around the first row paired holding part TH1 of the fifth rear plate pair PB5, the thread 3 is similarly and sequentially wound around the first-row paired holding part TH1 of the fourth rear plate pair PB4, the third rear plate pair PB3, the second rear plate pair PB2, and the first rear plate pair PB1. Then, the thread 3 passes through the first-row recess HK1 of the first rear holder plate BH1, and exits from the right side of the first rear holder plate BH1. As illustrated in FIG. 37, the rear first-row left-right extending portion 152 is located behind the loop held by the first row paired holding part TH1. The setting of the thread 3 may be performed mechanically, or may be performed partially or entirely manually.
After the state in FIG. 37, the knitting mechanism 103 moves the front needle unit 105 backward and shifts to the state in FIG. 38. In FIG. 38 (A), the first rear holder plate BH1 is not illustrated. Note that, although illustration of the front holder plate group 145 is omitted in FIG. 38 (the same applies to FIGS. 39 to 49 below), the front holder plate group 145 is in the pair separated state, and each of the paired needles 101 in the front needle unit 105 passes through each of the gaps in the plate pairs 140 of the front holder plate group 145 and then moves backward.
Shifting from the state in FIG. 37 to the state in FIG. 38 will be described focusing on the first front paired needle FA1. In the state in FIG. 37, the paired latch 110 of the first front paired needle FA1 is in the open state. However, the paired latch 110 may be in the closed state and shifted to the open state in a process of shifting to the state in FIG. 38 by using the thread 3, a magnet, or the like. The needle tip part 121 of the first front paired needle FA1, as the first front paired needle FA1 moves backward, enters the gap in the first rear plate pair PB1 and passes inside the loop held by the first-row paired holding part TH1 of the first rear plate pair PB1. In a case where the loop is held by the paired holding part 146 in the pair separated state, the paired holding part 146 holds the loop in a state that the inside of the loop is expanded. Thus, in the pair separated state, the needle tip part 121 can pass through inside the loop held by the paired holding part 146. Furthermore, the needle tip part 121 of the first front paired needle FA1 moves backward until the rear first-row left-right extending portion 152 is located above the paired latch 110 in the open state, and a tip of the paired latch 110 in the open state is located at the back of the loop held by the paired holding part 146.
After the state in FIG. 38 is achieved, the knitting mechanism 103 moves the front needle unit 105 forward to shift to the state in FIG. 39. Shifting from the state in FIG. 38 to the state in FIG. 39 will be described in detail focusing on the first front paired needle FA1. When the first front paired needle FA1 moves forward from the state in FIG. 38, the rear first-row left-right extending portion 152 is hooked and retained by the paired hook 122, and pulled by the paired hook 122. Since the paired hook 122 moves forward through inside the loop held by the first-row paired holding part TH1 of the first rear plate pair PB1, the thread 3 retained by the paired hook 122 is pulled by the paired hook 122 through inside the loop.
Further, in a process of moving the first front paired needle FA1 forward, the tip of the paired latch 110 in the open state abuts on a portion of the thread 3 suspended by a pair of the first-row holding parts HJ1, and the tip rides on the portion of the thread 3. When the first front paired needle FA1 further moves forward, the portion of the thread 3 applies to the paired latch 110 a force acting to shift the paired latch 110 to the closed state, and the paired latch 110 gradually closes to become the closed state. As a result, in the state in FIG. 39, the paired latch 110 is brought into the closed state, and the thread 3 is retained by the paired hook 122 of the first front paired needle FA1. The thread 3 is in the state of being pulled, passing through the loop held by the first-row paired holding part TH1. Referring to FIG. 36 (A), in this state, the thread 3 is passed through the loops on the first row in the first-layer knitted fabric to knit stitches on the first row in the first layer, and also new loops are formed on the second row in the first layer. Note that a dedicated mechanism for shifting the state of the paired latch 110, such as a mechanism for shifting the paired latch 110 from the closed state to the open state using a magnet, or a mechanism for bringing a member abut on the paired latch 110 to shift the paired latch 110 to the open state, may be provided to shift the paired latch 110 from the closed state using this type of mechanism.
After the state in FIG. 39 achieved, the knitting mechanism 103 brings the rear holder plate group 126 into the pair proximity state, and the state shifts to the state in FIG. 40. Next, the knitting mechanism 103 slightly moves (revolves) the rear holder plate group 126 downward to such an extent that the paired needle 101 of the front needle unit 105 and the second-row paired holding parts TH2 of the rear holder plate group 126 face each other in the front-back direction. Then, the knitting mechanism 103 passes the thread 3 supplied from the thread supply mechanism (not illustrated) from right to left through all the second-row recesses HK2 in the rear holder plate group 126 to shift to the state in FIG. 41. Hereinafter, in the state in FIG. 41, a portion of the thread 3 passing through each of the second row recesses HK2 in the rear holder plate group 126 and extending in the left-right direction is defined as a “rear second-row left-right extending portion 153”. The control unit 150 controls the routing mechanism to perform such routing of the thread 3. Next, the knitting mechanism 103 moves the front needle unit 105 backward to shift to the state in FIG. 43 via the state in FIG. 42. In FIG. 43 (A), illustration of the first rear holder plate BH1 and the second rear holder plate BH2 is omitted.
Shifting from the state in FIG. 41 to the state in FIG. 43 via the state in FIG. 42 will be described focusing on the first front paired needle FA1. When the first front paired needle FA1 moves backward from the state in FIG. 41, the portion of the thread 3 suspended by the pair of single hooks 113 eventually enters the second row paired recess TK2 of the first rear plate pair PB1. A tension for suppressing loosening (tension for pulling the thread 3) is applied to the thread 3, and the loop to be retained by the paired hook 122 shrinks as the first front paired needle FA1 moves backward. When the portion of the thread 3 suspended by the paired hook 122 comes to below the second-row paired holding part TH2 of the first rear plate pair PB1 (state in FIG. 42), and then further goes beyond the second-row paired holding part TH2 to the back, the force to move the portion backward and the tension applied to the thread 3 are balanced in the portion of the thread 3 suspended by the paired hook 122. As a result, the portion of the thread 3 almost does not further move backward. On the other hand, paired hook 122 moves backward.
Therefore, when the first front paired needle FA1 moves backward, the portion of the thread 3 suspended by the paired hook 122 eventually abuts on the inner side of the paired latch 110. When the first front paired needle FA1 further moves backward, the portion of the thread 3 applies the force to shift the paired latch 110 to the open state, and the paired latch 110 gradually opens and becomes the open state. When the first front paired needle FA1 further moves backward, the portion of the thread 3 retained by the paired hook 122 will come to the paired recess 123 of the first front paired needle FA1, and the movement of the first front paired needle FA1 will stop in this state. Then, when the rear holder plate group 126 is slightly revolved downward, the state in FIG. 43 is achieved.
After the state in FIG. 43 is achieved, the knitting mechanism 103 moves the front needle unit 105 forward to shift to the state in FIG. 45 via the state in FIG. 44. Shifting from the state in FIG. 43 to the state in FIG. 45 via the state in FIG. 44 will be described focusing on the first front paired needle FA1. When the first front paired needle FA1 starts to move forward from the state in FIG. 43, the first front paired needle FA1 moves relatively forward with respect to the portion of the thread 3 suspended in the paired recess 123, and the portion of the thread 3 abuts on the base of the paired latch 110 in the open state. When the first front paired needle FA1 further moves forward, the portion of the thread 3 is gradually advanced forward by being pushed by the paired latch 110, and a force to shift the paired latch 110 to the closed state is applied to the paired latch 110 to gradually close the paired latch 110. When the first front paired needle FA1 sill further moves forward, the relevant portion enters the inside of the second-row paired holding part TH2 via the inlet 117, and the paired latch 110 further becomes the closed state (state in FIG. 44).
When the first front paired needle FA1 further moves forward from the state in FIG. 44, as illustrated in FIG. 45, the loop comes off the first front paired needle FA1, the first front paired needle FA1 is located at a position spaced apart forward from the first rear plate pair PB1, and the loop is held by the second-row paired holding part TH2. As described above, in a series of operations from the state in FIG. 39 to the state in FIG. 45, the loops retained by the paired needles 101 in the front needle unit 105 are transferred to the second-row paired holding parts TH2 in the rear holder plate group 126. The loops held in the second-row paired holding parts TH2 in the state in FIG. 45 correspond to the loops on the second row in the first layer illustrated in FIG. 36 (A).
After the state in FIG. 45 is achieved, the knitting mechanism 103 slightly revolves the rear holder plate group 126 upward and also brings the rear holder plate group 126 into the pair separated state. Furthermore, the knitting mechanism 103 pulls the rear second-row left-right extending portion 153 forward with each of the paired needle 101 in the front needle unit 105 in the same manner as when shifting from the state in FIG. 37 to the state in FIG. 39. The thread 3 is passed through the inside of each loop held by the second-row paired holding part TH2. Thus, with reference to FIG. 36 (A), the stitches on the second row in the first layer are knitted, and also the loops on the third row in the first layer are newly formed. FIG. 46 illustrates a state in which the rear second-row left-right extending portion 153 is pulled by each of the paired needles 101 in the front needle unit 105, new loops on the third row in the first layer are formed by passing the thread 3 through the loops on the second row in the first layer, and the loops are retained by the paired needles 101 in the front needle unit 105.
As described above, under the control of the control unit 150, the knitting mechanism 103 knits stitches by passing the thread 3 through the existing loops (loops formed immediately before) held by one paired holding parts 146, and also forming new loops. These new loops are held by the paired holding parts 146 for a row one row above the one paired holding parts 146. This operation is sequentially executed in the column direction (=wale direction) to knit stitches stepwise. FIG. 47 illustrates a state in which the loops on the sixth row in the first layer are held by the sixth-row paired holding parts TH6 in the rear holder plate group 126, then the thread 3 is passed through the loops on the sixth row in the first layer to newly form loops on the seventh row in the first layer, and the loops formed are held by the seventh-row paired holding parts TH7 in the rear holder plate group 126. In the state in FIG. 47, the rear holder plate group 126 is in the pair separated state.
After the state in FIG. 47 is achieved, the knitting mechanism 103 moves the rear needle unit 104 forward to shift to the state in FIG. 48. In FIG. 48 (A), the first rear holder plate BH1 is not illustrated. In the state in FIG. 48, each of the loops held by each of the seventh-row paired holding parts TH7 is retained by each of the paired hooks 122 of the paired needles 101 in the rear needle unit 104.
After the state in FIG. 48 is achieved, the knitting mechanism 103 moves the rear needle unit 104 backward with the loop being retained by each of the paired hooks 122 in the rear needle unit 104 to shift the state to that in FIG. 49. In the state of FIG. 49, the loop held by each of the seventh-row paired holding part TH7 in the rear holder plate group 126 is released. The loop retained by each of the paired hooks 122 of the paired needles 101 in the rear needle unit 104 is the loop on the seventh row in the first layer and at the same time the loop in the first row in the second layer (see FIG. 36 (B)).
After the state in FIG. 49 is achieved, the knitting mechanism 103 passes the thread 3 through each of the first-row recesses HK1 in the front holder plate group 145 from left to right of the front holder plate group 145 to achieve the state in FIG. 50. As illustrated in FIG. 50, in the state in FIG. 50, the postures of the holder plates 127 in the rear holder plate group 126 and the holder plate 127 in the front holder plate group 145 are controlled such that the seventh-row holding parts HJ7 of the holder plates 127 in the rear holder plate group 126 and the first-row holding parts HJ1 of the holder plates 127 in the front holder plate group 145 face each other in the front-back direction. Hereinafter, in the portions of the thread 3, a portion extending in the left-right direction passing through each of the first-row recesses HK1 in the front holder plate group 145 is defined as a “front first-row left-right extending portion 155”.
After the state in FIG. 50 is achieved, the knitting mechanism 103 moves the rear needle unit 104 forward to shift to the state in FIG. 51. In FIG. 51 (A), the first rear holder plate BH1 in the rear holder plate group 126 is not illustrated. Shifting from the state in FIG. 50 to the state in FIG. 51 will be described focusing on the first rear paired needle BA1. When the first rear paired needle BA1 moves forward from the state in FIG. 50, the loop retained by the paired hook 122 moves backward relative to the first rear paired needle BA1 (=relatively moves to the base side), and eventually abuts on the paired latch 110 to apply a force to the paired latch 110 to shift from the closed state to the open state. When the first rear paired needle BA1 further moves forward and the loop is moved relatively back with respect to the first rear paired needle BA1 (=relatively moved to the base side), the paired latch 110 becomes the open state, and the loop comes off the paired hook 122 and goes over the tip of the paired latch 110 in the open state to the back, resulting in the state in FIG. 51.
After the state in FIG. 51 is achieved, the knitting mechanism 103 further moves the rear needle unit 104 forward to shift to the state in FIG. 52. In FIG. 52 (A), the moving rod is partially not illustrated. Shifting from the state in FIG. 51 to the state in FIG. 52 will be described focusing on the first rear paired needle BA1. When the rear needle unit 104 further moves forward from the state in FIG. 51, the loop moves relatively backward with respect to the first rear paired needle BA1 (=relatively moves to the base side), and eventually abuts on the paired pushing surface 124 of the needle base part 120. When the first rear paired needle BA1 further moves forward, the loop is pushed by the pushing surface 124 against the tension applied to the thread 3, and the state in FIG. 52 is achieved. In the state in FIG. 52, the portion of the thread 3 suspended by the paired needle 101 is located forward of the first-row paired holding part TH1 of the first front plate pair PF1 in the front holder plate group 145.
After the state in FIG. 52 is achieved, the knitting mechanism 103 moves the rear needle unit 104 backward to shift to the state in FIG. 53. In the process of shifting from the state of FIG. 52 to the state of FIG. 53, the loops suspended by the paired needles 101 in the rear needle unit 104 are transferred to the first-row paired holding parts TH1 in the front holder plate group 145 and retained by the first-row paired holding parts TH1 in the same manner as when shifting from the state of FIG. 43 to the state of FIG. 45 via the state in FIG. 44.
After the state in FIG. 53 is achieved, the knitting mechanism 103 brings the front holder plate group 145 into the pair separated state, and further revolves the front holder plate group 145 slightly upward. Then, the knitting mechanism 103 moves the rear needle unit 104 forward to such an extent that each of the paired hooks 122 in the rear needle unit 104 is located forward of the front first-row left-right extending portion 155 (FIG. 54). In FIG. 54 (A), the first front holder plate FH1 in the front holder plate group 145 is not illustrated. As illustrated in FIG. 54, in the state in FIG. 54, the needle tip part 121 of the paired needle 101 in the rear needle unit 104 passes through inside the loop held by the first-row paired holding part TH1 in the front holder plate group 145.
Next, the knitting mechanism 103 moves the rear needle unit 104 backward to shift to the state in FIG. 55. In FIG. 55 (A), the first rear holder plate BH1 in the rear holder plate group 126 is not illustrated. In a process of shifting from the state in FIG. 54 to the state in FIG. 55, the thread 3 is passed through the loops held by the first-row paired holding parts TH1 in the front holder plate group 145 (the loops on the seventh row in the first layer and at the same time the loops on the first row in the second layer) to knit stitches on the first row in the second layer and also form new loops retained by paired hooks 122 in the rear needle unit 104 (loops on the second row in the second layer).
Next, the knitting mechanism 103 brings the front holder plate group 145 into the pair proximity state, and then revolves the front holder plate group 145 downward to such an extent that the second-row holding parts HJ2 in the front holder plate group 145 and the seventh-row holding parts HJ7 in the rear holder plate group 126 face each other in the front-back direction. Furthermore, the knitting mechanism 103 passes the thread 3, from right to left of the front holder plate group 145, through each of the second-row recesses HK2 in the front holder plate group 145, so as to shift to the state in FIG. 56. Hereinafter, in the portions of the thread 3, a portion extending in the left-right direction passing through each of the second-row recesses HK2 in the front holder plate group 145 is defined as a “front second-row left-right extending portion 156”.
Next, the knitting mechanism 103 moves the rear needle unit 104 forward, and revolves the front holder plate group 145 slightly downward to shift to the state in FIG. 57. The knitting mechanism 103 further moves the rear needle unit 104 backward to shift to the state in FIG. 58. In FIG. 58, the first rear holder plate BH1 in the rear holder plate group 126 is not illustrated. By a series of operations from the state in FIG. 56 to the state in FIG. 58, the loops retained by the paired needles 101 in the rear needle unit 104 are transferred to the second-row paired holding parts TH2 in the front holder plate group 145, using a method similar to the series of operations from the state in FIG. 50 to the state in FIG. 53. Here, the loops held by the second-row paired holding parts TH2 are loops on the second row in the second layer.
Next, the knitting mechanism 103 revolves the rear holder plate group 126 upward to such an extent that the sixth-row holding parts HJ6 of the holder plates 127 in the rear holder plate group 126 and the second-row holding parts HJ2 of the holder plates 127 in the front holder plate group 145 face each other in the front-back direction. Next, the knitting mechanism 103 moves the rear needle unit 104 forward to such an extent that each of the paired hooks 122 goes forward beyond each of the loops held by each of the sixth-row paired holding parts TH6 in the rear holder plate group 126, so as to shift to the state in FIG. 59. In FIG. 59 (A), the first rear holder plate BH1 in the rear holder plate group 126 is not illustrated.
After the state in FIG. 59 (A) is achieved, the knitting mechanism 103 moves the rear needle unit 104 backward to shift to the state in FIG. 60. In FIG. 60 (A), the first rear holder plate BH1 in the rear holder plate group 126 and the first front holder plate FH1 in the front holder plate group 145 are not illustrated. In the state in FIG. 60, each of the loops held by each of the sixth-row paired holding parts TH6 in the rear holder plate group 126 (loops on the sixth row in the first layer) is transferred to each of the paired needles 101 in the rear needle unit 104. In other words, the knitting mechanism 103 hooks the loops in the first layer retained by the sixth-row paired holding parts TH6 (one holding parts of one holder forming members) of the holder plate 127 in the rear holder plate group 126 onto the paired hooks 122 of the pair needles 101 in the rear needle unit 104 (needle member).
Next, the knitting mechanism 103 moves the rear needle unit 104 forward to shift to the state in FIG. 61. In FIG. 61 (A), the first rear holder plate BH1 in the rear holder plate group 126 and the first front holder plate FH1 in the front holder plate group 145 are not illustrated. Shifting from the state in FIG. 60 to the state in FIG. 61 will be described focusing on the first rear paired needle BA1. The knitting mechanism 103 moves the first rear paired needle BA1 forward (the tip direction for the first rear paired needle BA1) so that the first rear paired needle BA1 passes through inside the loop in the second layer held by the second-row paired holding part TH2 (one holding part of the other holder forming member) of the first front plate pair PF1 in the front holder plate group 145. Along with this movement, the knitting mechanism 103 moves the loop in the first layer retained by the paired hook 122 relatively backward with respect to the first rear paired needle BA1 (base direction for the first rear paired needle BA1), and brings the loop of the first layer abut on the paired pushing surface 124. In the state in FIG. 61, the paired latch 110 is in the open state, and the tip part of the paired latch 110 is located in front of the portion of the thread 3 suspended by the second-row paired holding part TH2 of the first front plate pair PF1 of the front holder plate group 145. Furthermore, in the state in FIG. 61, the paired hook 122 of the first rear paired needle BA1 is located in front of the front second-row left-right extending portion 156.
After the state in FIG. 61 is achieved, the knitting mechanism 103 moves the rear needle unit 104 backward to shift to the state in FIG. 62. In FIG. 62 (A), the first rear holder plate BH1 in the rear holder plate group 126 and the first rear holder plate BH1 in the front holder plate group 145 are not illustrated. Shifting from the state in FIG. 61 to the state in FIG. 62 will be described focusing on the first rear paired needle BA1 in the rear needle unit 104. The knitting mechanism 103 causes the paired hook 122 of the first rear paired needle BA1 to retain the thread 3 located in front (the tip direction for the first rear paired needle BA1) of the loop in the second layer held by the second row paired holding part TH2 of the first front plate pair PF1 in the front holder plate group 145 (one holding part of the other holder forming member). The knitting mechanism 103 moves the first rear paired needle BA1 backward (the base direction for the first rear paired needle BA1) so that the thread 3 retained by the paired hook 122 passes through inside the loop in the second layer held by the second-row paired holding part TH2 of the first front plate pair PF1 in the front holder plate group 145. Along with this movement, the knitting mechanism 103 moves the loop in the first layer abutting on the paired pushing surface 124 forward (the tip direction for the first rear paired needle BA1) relative to the first rear paired needle BA1 while retaining the state in which the thread 3 is retained by the paired hook 122. The outer side of the paired latch 110 slides on the loop in the first layer to shift the paired latch 110 to the closed state, and at the same time the loop in the first layer goes forward beyond the paired hook 122 (the tip side for the first rear paired needle BA1).
As a result of performing the above operation to shift from the state in FIG. 61 to the state in FIG. 62, the thread 3 is passed through both the loops (loops on the second row in the second layer) held by the second-row paired holding parts TH2 in the front holder plate group 145 and the loops retained by the paired needles 101(=loops on the sixth row in the first layer). Thus, stitches on the second row in the second layer are knitted, and also loops on the third row in the second layer are newly formed. These newly formed loops are retained by the paired hooks 122 of the paired needles 101.
After the state in FIG. 62 is achieved, the knitting mechanism 103 revolves the front holder plate group 145 downward to such an extent that the third-row paired holding parts TH3 in the front holder plate group 145 and the sixth-row paired holding parts TH6 in the rear holder plate group 126 face each other in the front-back direction. Then, the knitting mechanism 103 passes the thread 3, from left to right of the front holder plate group 145, through each of the third-row recesses 131 in the front holder plate group 145 to shift to the state in FIG. 63. In FIG. 63, the first rear holder plate BH1 in the rear holder plate group 126 and the first rear holder plate BH1 in the front holder plate group 145 are not illustrated.
Hereafter, under the control of the control unit 150, the knitting mechanism 103 performs the same operation as the operation when shifting from the state in FIG. 56 to the state in FIG. 62 is performed to execute the following operation. More specifically, the knitting mechanism 103 knits stitches on the third row in the second layer and newly forms loops on the fourth row in the second layer by passing the thread 3 through both the loops on the third row in the second layer retained by the paired needles 101 in the rear needle unit 104 in the state in FIG. 63 and the loops on the fifth row in the first layer held by the fifth-row paired holding parts TH5 in the rear holder plate group 126 in the state in FIG. 63. The loops on the third row in the second layer are held by the third-row paired holding parts TH3 in the front holder plate group 145. In this way, the knitting mechanism 103 repeatedly performs the operation of knitting stitches and forming new loops by passing the thread 3 through both the loops formed most recently in the second layer and the corresponding loops in the first layer, so as to knit stitches stepwise in the column direction (so-called wale direction) thereby knitting the second-layer knitted fabric.
After knitting the second-layer knitted fabric, the knitting mechanism 103 turns back from the second layer to the third layer, and sequentially knits stitches in the third layer to knit the third-layer knitted fabric. As described above, turning back from the second layer to the third layer is different from the turning back from the first layer to the second layer with respect to a point that the thread 3 is passed through both the loops in the same layer (in this case, the third layer) and the loops in the layer immediately below (second layer in the present example) when knitting the stitches on the first row. Hereinafter, the turning back from the second layer to the third layer will be described using a side view.
FIG. 65 is the side view illustrating the operation of the knitting mechanism 103 when turning back from the second layer to the third layer. Time passes from (A) to (D).
FIG. 65(A) illustrates a state in which the front holder plate group 145 holds the loops on the first row to the seventh row in the second-layer knitted fabric. At the time point of FIG. 65(A), the second-layer knitted fabric is overlaid and connected to the first-layer knitted fabric in a portion surrounded by the broken line. However, for the sake of visibility of the drawing, the first-layer knitted fabric is omitted in each drawing of FIG. 65. After the state in FIG. 65(A) is achieved, the knitting mechanism 103 causes the rear holder plate group 126 to release the loops held by the first-row paired holding parts TH1 in the rear needle unit 104, and these loops are cast off. Note that the loops held by the first-row paired holding parts TH1 are the loops on the first row in the first layer (cast-on loops).
The operation of the knitting mechanism 103 at this point will be described focusing on the first rear paired needle BA1 in the rear needle unit 104. The knitting mechanism 103 moves the first rear paired needle BA1 to transfer the loop retained by the first-row paired holding part TH1 to the paired hook 122. Next, the knitting mechanism 103 moves forward the first rear paired needle BA1 in which the paired hook 122 retains the loop, and brings the loop to abut on the paired pushing surface 124. The first rear paired needle BA1 continues to move forward. The loop changes the paired hook 122 to the open state. Next, the knitting mechanism 103 moves the first rear paired needle BA1 backward. Along with this movement, the paired latch 110 becomes the closed state, and the loop slides on the outside of the paired latch 110 and comes off the paired needle 101. As a result, the loop is no longer retained. FIG. 65(B) shows the state of the knitting mechanism 103 after the loops held by the first-row paired holding parts TH1 in the rear holder plate group 126 are released.
After the state in FIG. 65(B) is achieved, the knitting mechanism 103 causes the first-row holding parts HJ1 in the rear holder plate group 126 and the seventh-row holding parts HJ7 in the front holder plate group 145 to face each other in the front and back direction. Next, the knitting mechanism 103 moves the front needle unit 105 to transfer the loops held by the seventh-row paired holding parts TH7 in the front holder plate group 145 (loops on the seventh row in the second layer and at the same time loops on the first row in the third layer) to the paired needle 101 in the front needle unit 105. Further, the thread 3 is routed so as to extend the thread 3 in the left-right direction in a state that the thread 3 is inserted into all the first-row recesses HK1 in the rear holder plate group 126, thereby achieving the state in FIG. 65(C).
Next, the knitting mechanism 103 controls the movement of the front needle unit 105 to transfer the loops retained by the front needle unit 105 to the first-row paired holding parts TH1 in the rear holder plate group 126 (state in FIG. 65(D)). Next, the knitting mechanism 103 controls the rear holder plate group 126, the front holder plate group 145, and the front needle unit 105 to pass the thread 3 extending in the left-right direction in the first-row recesses HK1 in the rear holder plate group 126 through both the loops on the first row in the third layer held by the first-row paired holding parts TH1 in the rear holder plate group 126 and the loops on the sixth row in the second layer held by the sixth-row paired holding part TH6 in the front holder plate group 145, so as to knit stitches on the first row in the third layer. The knitting mechanism 103 releases the retention of the loops on the sixth row in the second layer after stitches on the first row in the third layer are knitted. By knitting the stitches, the rear holder plate group 126 then holds loops on the second row in the third layer that are newly formed by the second-row paired holding part TH2. Thereafter, the thread 3 is passed through both the loops in the third layer and the corresponding loops in the second layer to knit stitches stepwise in the column direction (=wale direction).
As described above, in the present embodiment, the knitting mechanism 103 includes two holder plates 127 provided with the plurality of holding parts 132 capable of holding the plurality of loops formed in the column direction in one layer when focusing on one row of the knitted fabric. The knitting mechanism 103 causes one holding parts 132 of the holder plate 127 to hold the loops formed at the time of knitting the (N−1)th-layer knitted fabric even after the knitting of the (N−1)th-layer knitted fabric is completed. To knit stitches in the Nth-layer knitted fabric, the knitting mechanism 103 causes one holding parts 132 of the other holder plates 127 to hold the loops already formed in the Nth layer, and knit stitches by passing the thread through both the loops in the Nth layer held by the one holding parts 132 of the other holder plates 127 and the loops at a position corresponding to the position of the loop in the Nth layer held by the one holding parts 132 of the other holder plates 127, which are held by the one holding part 132 of the one holder plates 127 among the loops in the (N−1)th layer held by the holding parts 132 of the one holder plates 127. The retention of the loops in the (N−1)th layer by the one holding parts 132 of the one holder plates 127 are released as stitches are knitted. At the same time, the retention of the loops in the Nth layer by the one holding parts 132 of the other holder plates 127 continues even after the knitting of the Nth-layer knitted fabric is completed. According to this configuration, similarly to the first embodiment, the knitted product 2 having a solid three-dimensional shape formed of a plurality of layers of knitted fabrics can be knitted.
<Modified Example of Second Embodiment>
Next, a modified example of the second embodiment will be described. In the second embodiment, as in the case illustrated in FIGS. 41 to 45, when the loops retained by the paired hooks 122 of the paired needles 101 are transferred to the paired holding parts 146, as illustrated in FIG. 43, the paired needles 101 (the first front paired needle FA1 in the example in FIG. 43) are located above the thread 3 extending in the recesses 131 (the rear second-row left-right extending portion 153 in the example in FIG. 43). However, as illustrated in FIG. 66, the paired needle 101 may be located below the thread 3. When the front needle unit 105 moves forward from the state in FIG. 66, the paired latch 110 is closed by the thread 3, and thus the loop can be retained by the paired holding part 146 without entering the thread 3 into the paired hook 122. Note that the sheet feed mechanism applies a tension to retain the rear second-row left-right extending portions 153 at this position. Therefore, the position in FIG. 66 is retained.
Furthermore, the paired needle 101 may have the following structure. FIG. 67 illustrates a paired needle 160, which is a modified example of the paired needle 101 according to the second embodiment. As illustrated in FIG. 67, the paired needle 160 includes a housing 161 and a needle body 162 movable between a first position (FIGS. 67(A) and (B)) and a second position (FIG. 67(C)) relative to the inside of the housing 161. As illustrated in FIGS. 67(A) and (B), when the needle body 162 is at the first position with respect to the housing 161, the paired latch 163 is located outside the housing 161, and can be in either an open state or a closed state. On the other hand, assume that the paired latch 163 of the needle body 162 located at the first position is in the open state as illustrated in FIG. 67(B). When the needle body 162 moves from this state to the second position, as illustrated in FIG. 67(C), the paired latch 163 is housed in the latch housing 164 formed in the housing 161, and the paired latch 163 is locked in the open state.
The paired latch 163 is used, for example, in the following manner. FIG. 68 illustrates a usage of the paired latch 163. Now, the knitting mechanism 103 is in the state in FIG. 68(A), and the loop retained by the paired needle 160 from this state is transferred to the second-row paired holding part TH2. Note that the first rear holder plate BH1 is appropriately moved, and the description of the movement of the first rear holder plate BH1 is omitted.
From the state in FIG. 68(A), the knitting mechanism 103 moves the paired needle 160 backward and also shifts the paired latch 163 to the open state. Then, the needle body 162 moves to the second position to house the paired latch 163 in the open state into the latch housing 164 (FIG. 68(B)). Next, the knitting mechanism 103 moves the paired needle 160 forward to retain the loop by the second-row paired holding part TH2 (FIG. 68(C)). Next, the knitting mechanism 103 moves the paired needle 160 backward and also moves the needle body 162 to the first position (FIG. 68(D)). In the state in FIG. 68(D), the paired latch 163 is in the open state. The knitting mechanism 103 moves the paired needle 160 forward from the state in FIG. 68(D) to the state in FIG. 68(E). In a process of shifting from FIG. 68(D) to FIG. 68(E), the paired latch 163 contacts the thread 3 and becomes the closed state. In the second embodiment and the modified example thereof, the paired needles 101 and 160 have the paired recess 123, but the paired recess 123 may not be provided.
Conditions of the knitted product 2 knitted by the knitting mechanism 103 of the knitting machine 100 according to the second embodiment is not limited to that exemplified in the second embodiment. The knitting method differs depending on conditions of the knitted product 2 to be knitted. For example, in the embodiment described above, the thread 3 is not passed through the loops in the first layer for the stitches on the first row in the second layer when the thread 3 is turned back from the first layer to the second layer. In this regard, when knitting stitches on the first row in the second layer, the thread 3 may be passed through the loops on the first row in the second layer and the loops on the fifth row in the second layer (not the sixth row in the second layer). In addition, in the second embodiment, the thread 3 is passed through the loops on the second row in the second layer and the sixth row in the first layer. However, the combination of the Nth layer and the (N−1)th layer through which the thread 3 is simultaneously passed is not limited to that exemplified in the above embodiment. For example, the thread 3 may be passed through the loops on the second row in the second layer and the loops on the fifth row in the first layer. In addition, the moving rod and the appropriate holder plate 127 may be directly bonded or integrally molded. The method for bringing the rear holder plate group 126 and the front holder plate group 145 into the pair proximity state and the pair separated state is not limited to the method exemplified in the present embodiment.
In addition, the number of rows in each layer does not need to be equivalent. For example, the second layer may have seven rows and the third layer may have six rows. Or, the second layer may have six rows, and the third layer may have seven rows. When the number of rows in the Nth layer is smaller than the number of rows in the (N−1)th layer, loops held in the (N−1)th layer through which the thread 3 does not pass together with the loops in the Nth layer may be released using the same method as the method described with reference to FIG. 65 (A). When the number of rows in the Nth layer is larger than the number of rows in the (N−1)th layer, the thread 3 is passed through only the loops in the Nth layer, such as in the turning back from the first layer to the second layer in the example of the second embodiment, so as to form new loops to increase the number of rows. Thus, the shape of the knitted product 2 can be controlled by increasing or decreasing the number of rows in each layer.
In the embodiment described above, to transfer a loop retained by the paired needle 101 to the paired holding part 146, the rear holder plate group 126 (or the front holder plate group 145) is in the pair proximity state to transfer the loop retained by the thread 3 to the paired holding part 146 by operating the paired needle 101 in the above-described manner. On the other hand, to transfer the loop held by the paired holding part 146 to the paired needle 101, the rear holder plate group 126 (or the front holder plate group 145) is in the pair separated state, and the paired needle 101 is operated in the above-described manner to transfer the loop held by the paired holding part 146 to the paired needle 101. Still more, to pass the thread 3 through the loop held by the paired holding part 146, the rear holder plate group 126 (or the front holder plate group 145) is in the pair separated state, and the paired needle 101 is operated to pass the thread 3 retained by the paired needle 101 through inside the loop. However, the structural features of each member and the operation of each member for realizing the transfer of loops and the knitting of stitches are not limited to those exemplified in the above embodiment. For example, the paired needle 101 may be configured such that a distance between one single needle 112 and the other single needle 112 can be changed, while a distance between the pair of holding parts 132 in the paired holding part 146 is fixed. To transfer a loop from the paired needle 101 to the paired holding part 146, a width of a gap in the paired needle 101 may be made larger than a width of a gap in the paired holding part 146 to hook and transfer the thread 3. To transfer a loop from the paired holding part 146 to the paired needle 101, the width of the gap in the paired needle 101 may be made smaller than the width of the gap in the paired holding part 146 to hook and transfer the thread 3. Furthermore, to knit a stitch, the width of the gap in the paired needle 101 may be made smaller than the width of the gap in the paired holding part 146 to pass the thread 3 retained by the paired needle 101 through the loop held by the paired holding part 146.
Although the two embodiments (including the modified examples) of the present invention have been described above, the above embodiments are merely examples of embodying the present invention, and the technical scope of the present invention should not be interpreted in a limited manner. In other words, the present invention can be implemented in various forms without departing from the gist or main features thereof. In particular, it goes without saying that the structure of the knitting machine 100 is not limited to the structure in each embodiment. More specifically, the present invention broadly includes the knitting machine including the knitting mechanism, wherein the knitting mechanism retains loops formed when knitting the (N−1)th-layer knitted fabric (N being an integer of 2 or more) even after completion of the knitting of the (N−1)th-layer knitted fabric, and when knitting stitches in an Nth-layer knitted fabric, retains the loops already formed in the Nth layer, knits the stitches by passing the new thread through both the loops already formed and retained in the Nth layer and, of the loops retained in the (N−1)th layer, loops at corresponding positions to the loops already formed in the Nth layer, and releases retention of the loops at the corresponding positions in accordance with the knitting of the stitches while continuing to retain the loops already formed in the Nth layer even after completion of the knitting of the Nth-layer knitted fabric. The structural features and the operations are not limited to those exemplified in the first embodiment and the second embodiment. Furthermore, regarding the knitted fabric of a certain layer, the loops retained even after the completion of the knitting of the layer of knitted fabric may not be all the loops in the layer as long as the thread 3 is passed through some loops in the layer together with loops in the next layer to knit stitches in the next layer.

REFERENCE SIGNS LIST

1, 100 knitting machine
4 needle
3 thread
7, 103 knitting mechanism
14 hook
16 holder
60 holding part
101, 160 paired needle (needle member)
110, 163 paired latch (latch)
120 needle base part
121 needle tip part
121 paired hook (hook member)
124 paired pushing surface (pushing surface)
127 holder plate (holder forming member)
132 holding part (holding portion)

Claims

1. A knitting machine comprising a knitting mechanism configured to knit a knitted product by overlaying a knitted fabric in a plurality of layers, wherein

the knitting mechanism:

retains loops formed when knitting an (N−1)th-layer knitted fabric (N being an integer of 2 or more) even after completion of the knitting of the (N−1)th layer knitted fabric, and

when knitting stitches in an Nth-layer knitted fabric, retains loops already formed in the Nth layer, knits the stitches by passing a new thread through both the loops already formed and retained in the Nth layer and, of the loops retained in the (N−1)th layer, loops at corresponding positions to the loops already formed in the Nth layer, and releases retention of the loops at the corresponding positions in accordance with the knitting of the stitches while continuing to retain the loops already formed in the Nth layer even after completion of the knitting of the Nth-layer knitted fabric.

2. The knitting machine according to claim 1, wherein

the knitting mechanism includes a plurality of holders arranged on a plurality of rows in a column direction, and a needle capable of retaining a loop,

each of the plurality of holders has two holding parts independently provided that are capable of holding a loop and releasing the holding of the loop,

the holding parts of holders are capable of receiving the loop retained on the needle, and

in the knitting mechanism,

one holding part in each of the plurality of holders holds each of a plurality of stitch loops arranged on the plurality of rows in the column direction in the (N−1)th layer even after the completion of the knitting of the (N−1)th-layer knitted fabric,

when knitting stitches on a predetermined row in the Nth-layer knitted fabric, other holding part in each of the plurality of holders for the predetermined row holds a loop formed on a row immediately preceding the predetermined row in the Nth layer, the stitches are knitted by passing the needle retaining a thread through both the loop in the Nth layer held and a loop in the (N−1)th layer held by the one holding part in each of the plurality of holders for the predetermined row, the one holding part releases the loop in the (N−1)th layer held after knitting the stitches while the other holding part of each of the plurality of holders for the predetermined row continues to hold the loop in the Nth layer even after the completion of the knitting of the Nth-layer knitted fabric, and the other holding part in each of the plurality of holders for a row next to the predetermined row receives and holds a loop retained on the needle.

3. The knitting machine according to claim 2, wherein

when knitting the Nth-layer knitted fabric, the knitting mechanism knits stitches stepwise in the column direction by repeating an operation of:

knitting stitches by passing the needle retaining the thread through both the loop in the Nth layer held by the other holding part in each of the plurality of holders for the predetermined row and the loop in the (N−1)th layer held by the one holding part in each of the plurality of holders for the predetermined row, receiving and holding the loop retained on the needle by the other holding part in each of the plurality of holders for the row next to the predetermined row, and knitting stitches by passing the needle retaining the thread through both the loop in the Nth layer held by the other holding part in each of the plurality of holders for the row next to the predetermined row and the loop in the (N−1)th layer held by the one holding part.

4. The knitting machine according to claim 3, wherein

the needle is capable of moving in a horizontal direction intersecting a top-bottom direction while retaining a position in the top-bottom direction that is a direction to overlay a layer of the knitted fabric,

each of the plurality of holders is capable of moving in the top-bottom direction across a position of the needle in the top-bottom direction, and

when knitting the Nth-layer knitted fabric, the knitting mechanism:

elevates the plurality of holders for the predetermined row, including the other holding part holding the loop in the Nth layer and the one holding part holding the loop in the (N−1)th layer, to a position above the position of the needle in the top-bottom direction, and knits the stitches by horizontally moving the needle retaining the thread such that the needle passes through two loops elevated by the plurality of holders for the predetermined row.

5. The knitting machine according to claim 4, wherein

when knitting the Nth-layer knitted fabric, the knitting mechanism:

elevates the plurality of holders for the predetermined row, including the other holding part holding the loop in the Nth layer and the one holding part holding the loop in the (N−1)th layer, to a position above the position of the needle in the top-bottom direction,

knits the stitches by horizontally moving the needle retaining the thread such that the needle passes through the two loops elevated by the plurality of holders for the predetermined row and a portion of the needle retaining a loop is located at a position above the plurality of holders for the row next to the predetermined row, and

receives the loop retained on the needle by the other holding part by elevating the plurality of holders for the row next to the predetermined row.

6. The knitting machine according to claim 5, wherein

the holding part receives the loop from the needle by gripping the loop retained on the needle,

the needle has a pair of hooks in a forked manner for retaining the loop, the loop being retained across the pair of hooks and the pair of hooks being capable of shifting to a gap state in which a gap is formed between the pair of hooks to allow a portion for gripping the loop of the holding part to enter, and

in the knitting mechanism,

when the holding part of each of the plurality of holders receives the loop retained on the needle,

the holding part grips the loop by shifting the needle to the gap state, elevating the plurality of holders, and allowing the portion of the holding part for gripping the loop to enter the gap formed between the pair of hooks of the needle.

7. The knitting machine according to claim 2,

wherein

the two holding parts of each of the plurality of holders are arranged at positions symmetrical about a symmetric point, and each of the plurality of holders is revolvable about the symmetric point while the two holding parts are retained at the positions symmetrical about the symmetric point, and

in the knitting mechanism,

a holding part on a lower side of the symmetric point of the two holding parts in each of the plurality of holders holds each of the plurality of stitch loops arranged on the plurality of rows in the column direction in the (N−1)th layer even after the completion of the knitting of the (N−1)th-layer knitted fabric, and

when knitting stitches on the predetermined row in the Nth-layer knitted fabric, a holding part on an upper side of the symmetric point of the two holding parts in each of the plurality of holders holds the loop formed on the row immediately preceding the predetermined row in the Nth layer, the stitches are knitted by passing the thread through the loop in the Nth layer held and the loop in the (N−1)th layer held by the holding part on the lower side of the symmetric point in each of the plurality of holders for the predetermined row, the holding part on the lower side releases the loop in the (N−1)th layer held after knitting the stitches, and the plurality of holders is made to revolve about the symmetric point while the holding part on the upper side continues to hold the loop in the Nth layer, so that the holding part holding the loop in the Nth layer comes to the lower side of the symmetric point.

8. The knitting machine according to claim 7, wherein

knitting stitches by passing the needle retaining the thread through both the loop in the Nth layer held by the holding part on the upper side of the symmetric point in each of the plurality of holders for the predetermined row and the loop in the (N−1)th layer held by the holding part on the lower side of the symmetric point in each of the plurality of holders for the predetermined row, receiving and holding the loop retained on the needle by the holding part on the upper side of the symmetric point in each of the plurality of holders for the row next to the predetermined row, and knitting stitches by passing the needle retaining the thread through both the loop in the Nth layer held by the holding part on the upper side in each of the plurality of holders for the row next to the predetermined row and the loop in the (N−1)th layer held by the holding part on the lower side.

9. The knitting machine according to claim 8, wherein

when knitting the Nth-layer knitted fabric, the knitting mechanism:

elevates the plurality of holders for the predetermined row, including the holding part on the upper side of the symmetric point holding the loop in the Nth layer and the holding part on the lower side of the symmetric point holding the loop in the (N−1)th layer, to a position above the position of the needle in the top-bottom direction, and

knits the stitches by horizontally moving the needle retaining the thread such that the needle passes through two loops elevated by the plurality of holders for the predetermined row.

10. The knitting machine according to claim 9, wherein

when knitting the Nth-layer knitted fabric, the knitting mechanism:

elevates the plurality of holders for the predetermined row, including the holding part on the upper side of the symmetric point holding the loop in the Nth layer and the holding part on the lower side of the symmetric point holding the loop in the (N−1)th layer, to the position above the position of the needle in the top-bottom direction,

knits the stitches by horizontally moving the needle retaining the thread such that the needle passes through the two loops elevated by the plurality of holders for the predetermined row and a portion of the needle retaining the loop is located at a position above the plurality of holders for the row next to the predetermined row, and

receives the loop retained on the needle by the holding part on the upper side of the symmetric point by elevating the plurality of holders for the row next to the predetermined row.

11. The knitting machine according to claim 10, wherein

the needle has a pair of hooks in a forked manner for retaining the loop, the loop being retained across the pair of hooks and the pair of hooks being capable of shifting to a gap state in which a gap is formed between the pair of hooks to allow a portion of the holding part for gripping the loop to enter, and

in the knitting mechanism,

when the holding part on the upper side of the symmetric point of each of the plurality of holders receives the loop retained on the needle,

the holding part grips the loop by shifting the needle to the gap state, and allowing the portion for gripping the loop of the holding part on the upper side to enter the gap formed between the pair of hooks of the needle.

12. The knitting machine according to claim 1, wherein

the knitting mechanism includes two holder forming members having a plurality of holding parts that can hold a plurality of loops formed in a column direction in one layer,

in the knitting mechanism,

the plurality of holding parts in one holder forming member of the two holder forming members hold the loops formed when knitting the (N−1)th-layer knitted fabric even after completion of the knitting of the (N−1)th layer,

when knitting stitches in the Nth-layer knitted fabric, one holding part of the plurality of holding parts in other holder forming member of the two holder forming members holds a loop already formed in the Nth layer, the stitches are knitted by passing a thread through both the loop in the Nth layer held by the one holding part of the other holder forming member and, of the loops in the (N−1)th layer held by the holding parts of the one holder forming member, a loop retained by one holding part of the plurality of holding parts of the one holder forming member at a corresponding position to the loop in the Nth layer held by the one holding part of the other holder forming member, and the one holding part of the other holder forming member continues to hold the loop in the Nth layer even after the completion of the knitting of the Nth-layer knitted fabric while the one holding part of the one holder forming member releases the loop retained in the (N−1)th layer.

13. The knitting machine according to claim 12, wherein

in the knitting mechanism, the other holding part of the other holder forming member holds a new loop formed by knitting a stitch in the loop in the Nth layer and the loop in the (N−1)th layer, and the other holding part of the other holder forming member continues to hold the new loop even after the completion of the knitting of the Nth-layer knitted fabric.

14. The knitting machine according to claim 12, wherein

the two holder forming members are configured such that any of the holding parts in one of the two holder forming members and any of the holding parts in other of the two holder forming members can face each other by changing mutual orientations,

the holding parts are capable of retaining loops in a state whose inside is enlarged, and

in the knitting mechanism,

when knitting stitches in the Nth-layer knitted fabric, the one holding part in the other holder forming member and the one holding part in the one holder forming member face each other to make the loops retained by the holding parts face each other, and stitches are knitted by moving a needle retaining a thread such that the thread passes inside the loops retained by the holding parts.

15. The knitting machine according to claim 14, wherein the knitting mechanism transfers a new loop formed according to the knitting of stitches by movement of a needle to other holding part of the other holder forming member, and continues to hold the new loop by the other holding part of the other holder forming member even after the completion of the knitting of the Nth-layer knitted fabric.

16. The knitting machine of claim 14, wherein

the two holder forming members are configured such that any of the holding parts in one of the two holder forming members and any of the holding parts in other of the two holder forming members can face each other in a first direction by changing mutual orientations,

the needle is configured to be movable in a tip direction toward a tip side and a base direction toward a base side in the first direction, and includes a needle base part on which a pushing surface is formed, a needle tip part having a hook capable of retaining the thread, and a latch that opens and closes an inlet of the hook,

when a loop retained on the hook relatively advances to the base side with respect to the needle, an open state of the latch is retained in a condition that the latch is open and the loop pushes the latch to open in a condition that the latch is in a closed state,

when the loop is relatively further moved to the base side, the loop moves beyond the latch toward the base side, abuts on the pushing surface of the needle base part, and is pushed by the pushing surface,

when the loop relatively moves to the tip side with respect to the needle in a condition that the loop is located at the base side from the latch in the open state, the loop abuts on an outer side of the latch and the loop pushes the latch to the closed state as the loop further relatively moves to the tip side, slides on the outer side of the latch without entering the hook via the inlet, and moves beyond the tip side of the hook as the loop further relatively moves to the tip, and

in the knitting mechanism,

when stitches are knitted in the Nth-layer knitted fabric in a condition that the other holder forming member is disposed on the tip side with respect to the one holder forming member,

the one holding part of the other holder forming member faces the one holding part of the one holder forming member, the hook of the needle hooks a loop in the (N−1)th layer held by the one holding part of the one holder forming member, then the needle moves to the base side to retain a loop in the (N−1)th layer onto the hook, the needle moves to the tip side so as to pass the needle through inside the loop in the Nth layer retained by the one holding part of the other holder forming member, the loop in the (N−1)th layer retained by the hook is relatively moved to the base side with respect to the needle so that the loop in the (N−1)th layer abuts on the pushing surface, the hook retains the thread toward the tip side from the loop in the Nth layer retained by the one holding part of the other holder forming member, the needle moves to the base side so that the thread retained by the hook passes inside the loop in the Nth layer retained by the one holding part of the other holder forming member, the loop in the (N−1)th layer abutting on the pushing surface is relatively moved to the tip side with respect to the needle, the loop in the (N−1)th layer slides on an outer side of the latch to shift the latch to the closed state, the loop in the (N−1)th layer moves beyond the hook on the tip side, and stitches are knitted by passing the thread retained on the hook through both the loop in the (N−1)th layer and the loop in the Nth layer.

17. The knitting machine according to claim 16, wherein

in the knitting mechanism,

after a new loop is formed by passing the thread retained by the hook through both the loops in the (N−1)th layer and the Nth layer, an orientation of the other holder forming member is changed so that the needle faces the other holding part of the other holder forming member, the needle moves toward the tip side until the pushing surface of the needle is located beyond the other holding part of the other holder forming member toward the tip side, the new loop abuts on the pushing surface in line with the movement, the needle moves toward the base side, the loop abuts on the outer side of the latch to shift the latch to the closed state in line with the movement, the loop rides on the latch shifting to the closed state, and the loop on the latch is transferred to the other holding part of the other holder forming member.

18. A knitting method for a knitting mechanism that knits a knitted product by overlaying a knitted fabric in a plurality of layers, comprising:

retaining loops formed when knitting an (N−1)th-layer knitted fabric even after completion of the knitting of the (N−1)th-layer knitted fabric; and

when knitting stitches in an Nth-layer knitted fabric with the knitting mechanism, retaining loops already formed in the Nth layer, knitting the stitches by passing loops through both the loops already formed and retained in the Nth layer and, of the loops retained in the (N−1)th layer, loops at corresponding positions to the loops already formed in the Nth layer, and continuing to retain the loops already formed in the Nth layer even after completion of the knitting of the Nth-layer knitted fabric while releasing the retention of the loops at the corresponding positions in accordance with the knitting of the stitches.