WO2006129920A1

WO2006129920A1 - Knitting machine, knitted fabric and socks there by

Info

Publication number: WO2006129920A1
Application number: PCT/KR2006/001644
Authority: WO
Inventors: Min-Jae Kim
Original assignee: Millinet Co., Ltd.
Priority date: 2005-05-30
Filing date: 2006-05-02
Publication date: 2006-12-07
Also published as: KR100521409B1

Abstract

Disclosed herein is a knitting machine, and a knitted fabric and socks including heating threads fabricated thereby in which the heating threads, which are formed by coating conductive metallic wires, such as copper wires, etc., with an insulating material, are woven together with general threads, etc., thereby enabling fabrication of insulated clothes for cold environments, such as for example, socks, gloves, vest, muffler, cap, and the like, and the feed rate and tension of the heating threads during knitting of the fabric can be regulated so as to prevent snapping of the heating threads. The knitting machine comprises a cylinder(3), a plurality of needles(l) and sinkers(2) arranged along an inner diameter portion of the cylinder, thread guiding assemblies for guiding general threads to the needles and sinkers for the knitting of a fabric, a weft thread guiding assembly(4A) for guiding a heating thread as a weft thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers, a warp thread guiding assembly(4B) for guiding a heating thread as a warp thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers, and a heating thread tension regulating mechanism for regulating a tension of the heating thread as the weft thread being guided to the weft thread guiding assembly.

Description

KNITTING MACHINE, KNITTED FABRIC AND SOCKS THERE

BY

Technical Field

[1] The present invention relates to a knitting machine, and a knitted fabric and socks including heating threads fabricated thereby, and more particularly, to a knitting machine, and a knitted fabric and socks including heating threads fabricated thereby, wherein the heating threads, which are formed by coating conductive metallic wires, such as copper wires, etc., with an insulating material, are woven together with general threads, etc., thereby enabling fabrication of insulated clothes for cold environments, such as for example, socks, gloves, vest, muffler, cap, and the like, and the feed rate and tension of the heating threads during knitting of the fabric can be regulated so as to prevent snapping of the heating threads. Background Art

[2] In general, a knitting machine is used to automatically knit clothes, such as socks, gloves, vest, muffler, cap, and the like, and is able to make a variety of patterns in a simplified manner while its operation is controlled by a computer.

[3] Conventionally, a knitting machine includes a plurality of needles and sinkers for use in a knitting operation. Specifically, approximately two hundred needles are arranged along an inner diameter portion of a cylinder to reciprocally move in a vertical direction, and approximately the same number of sinkers are interposed between the respective neighboring needles at a right angle to the needles in a horizontally movable manner. Also, thread guiding assemblies are installed above the needles and sinkers such that threads, having passed through the thread guiding assemblies, are caught by upper ends of the sinkers.

[4] In operation, if the cylinder rotates, the plurality of needles arranged in the cylinder along a circumferential direction thereof are reciprocally moved in a vertical direction by a cam, so as to pull down the threads caught by the sinkers, resulting in knitting of a fabric.

[5] However, the conventional knitting machine has no ability of knitting a fabric including heating threads that are formed by coating conductive metallic wires, such as copper wires, with an insulating material. The heating threads formed by coating copper wires with an insulating material have less flexibility (flexuous deformation ability) than general threads, such as for example, cotton threads, synthetic fiber threads, etc. For this reason, if a certain tension is applied to the heating threads during interlacing of the threads by the needles and sinkers, the heating threads may easily snap and thus, may loss their heating function.

[6] As a solution of the above described problem, Korean Utility Model Publication

No. 20-0206458 discloses a knitted fabric fabricated by knitting weft and warp threads made of copper wires with each other in an interlacing method not requiring flexibility and free from tension, or by manually weaving heating threads with a knitted fabric fabricated by knitting general threads.

[7] However, the simple interlacing method is difficult to be applied in various clothes including socks, etc. Even if it is applied, resulting products inevitably have a significant deterioration in quality compared to products knitted by a knitting machine and thus, are unpractical. Also, the manual weaving operation is inefficient, resulting in deterioration of productivity as well as increased production costs. Disclosure of Invention Technical Problem

[8] Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a knitting machine capable of weaving heating threads, which are fabricated by coating conductive metallic wires, such as copper wires, with an insulating material, together with general threads, etc.

[9] It is another object of the present invention to provide a knitted fabric including heating threads, which enables the fabrication of insulated clothes for cold environments, such as socks, gloves, vest, muffler, cap, and the like.

[10] It is yet another object of the present invention to provide healthy socks, which can achieve not only thermal insulation effect against the cold by virtue of heating threads knitted therein, but also sterilization, antibacterial, deodorization and blood circulation promoting functions by silver ions emitted from a silver thread knitted therein as well as emission of far-infrared rays from bio-ceramics attached thereto. Technical Solution

[11] In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a knitting machine comprising a cylinder, a plurality of needles and sinkers arranged along an inner diameter portion of the cylinder, and thread guiding assemblies for guiding general threads to the needles and sinkers for the knitting of a fabric, further comprising: a weft thread guiding assembly for guiding a heating thread as a weft thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers; a warp thread guiding assembly for guiding a heating thread as a warp thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers; and a heating thread tension regulating mechanism for regulating a tension of the heating thread as the weft thread being guided to the weft thread guiding assembly.

[12] Preferably, the tension regulating mechanism may comprise: a rotatably installed feed reel, on which the heating thread as the weft thread is wound; a step motor for rotating the feed reel; guide means for guiding the heating thread as the weft thread being fed from the feed reel to the weft thread guiding assembly; a controller for controlling a rotating speed of the step motor; and an input device for inputting a control signal to the controller.

[13] In accordance with another aspect of the present invention, there is provided a knitted fabric comprising: a first knitted structure produced by knitting a heating thread as a weft thread and a plurality of strands of general threads by use of needles of an odd number group; a second knitted structure produced by knitting a plurality of strands of general threads by use of needles of an even number group at the same knitting position as that of the first knitted structure, the second knitted structure surrounding the first knitted structure; and a third knitted structure produced by knitting a plurality of strands of general threads by use of the needles of the odd and even number groups, the third knitting structure serving to maintain a predetermined distance between the neighboring first knitted structures, wherein the first to third knitted structures constitute a set of knitted structures obtained via a one-time operation, and the knitted fabric is fabricated by repeatedly producing the set of knitted structures.

[14] Preferably, the set of knitted structures obtained via a one-time operation may further comprise a fourth knitted structure produced between the first knitted structure and the third knitted structure by knitting a plurality of strands of general threads by use of the needles of the odd number group, the fourth knitted structure covering the first knitted structure by allowing the general threads to protrude from a surface thereof.

[15] Preferably, the set of knitted structures obtained via a one-time operation may further comprise a fifth knitted structure produced between the first knitted structure and the following knitted structure by knitting a heating thread as a warp thread by use of a selected one of the needles of the odd or even number group

[16] In accordance with yet another aspect of the present invention, there is provided socks fabricated by knitting general threads comprising: a heating thread as a weft thread spirally arranged in sequence by a predetermined distance in a longitudinal direction of a sock body; a heating thread as a warp thread arranged linearly along the longitudinal direction of the body and having one end electrically connected to one end of the heating thread as the weft thread; and a power supply device electrically connected to the other end of the heating thread as the weft thread and the other end of the heating thread as the warp thread and adapted to supply power to the heating threads as the weft and warp threads.

[17] Preferably, a plurality of thin bio ceramic plates may be arranged on a bottom portion of the body, and the general threads for use in the production of the body may include a silver thread.

[18] Preferably, the power supply device may comprise: a first terminal unit provided on the body and electrically connected to the ends of the heating threads as the weft and warp threads; a second terminal unit electrically connected to the first terminal unit in a detachable manner; a power source electrically connected to the second terminal unit and adapted to supply power; and a regulator for regulating a voltage or current supplied from the power source.

[19]

Advantageous Effects

[20] With a knitting machine in accordance with the present invention, heating threads, which are formed by coating conductive metallic wires, such as copper wires, etc., with an insulating material can be fed by use of weft thread and warp thread guiding assemblies such that a tension of the heating threads can be automatically regulated in the course of being fed to needles and sinkers of the knitting machine. This has the effect of eliminating the risk of snapping of the heating threads, thus enabling stable knitting of a fabric including the heating threads.

[21] Further, the knitted fabric including the heating threads fabricated by the knitting machine of the present invention can be used in the manufacture of insulated clothes for cold environments, such as for example, socks, gloves, vest, muffler, cap, and the like.

[22] Furthermore, the present invention can provide healthy socks fabricated by the knitting machine, which can be used as insulated articles for cold environments and have sterilization, antibacterial, deodorization and blood circulation promotion functions by virtue of emission of far-infrared rays from bio-ceramics as well as silver ions emitted from a silver thread knitted therein. Brief Description of the Drawings

[23] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[24] FIG. 1 is a perspective view illustrating important parts of a knitting machine in accordance with the present invention;

[25] FIG. 2 is a plan view of the important parts of the knitting machine in accordance with the present invention;

[26] FIG. 3 is a perspective view illustrating a tension regulating mechanism for regulating a tension of heating threads included in the knitting machine in accordance with the present invention; [27] FIG. 4 is a block diagram illustrating the control configuration of a step motor included in the heating thread tension regulating mechanism of the knitting machine in accordance with the present invention; [28] FIG. 5 is a front view illustrating a feed rate sensing unit included in the heating thread tension regulating mechanism of the knitting machine in accordance with the present invention;

[29] FIG. 6 is a sectional view taken along the line A-A of FIG. 5;

[30] FIG. 7 is a front view illustrating a feed tension sensing unit included in the heating thread tension regulating mechanism of the knitting machine in accordance with the present invention; [31] FIG. 8 is a flow chart illustrating the operation of a controller included in the heating thread tension regulating mechanism of the knitting machine in accordance with the present invention; [32] FIG. 9 is a life-size photograph illustrating the knitted structure of a knitted fabric including heating threads in accordance with the present invention; [33] FIG. 10 is a life-size photograph illustrating a vertically pulled and spread state of the knitted structure of FIG. 9; [34] FIG. 11 is a process view illustrating a method for knitting the fabric including heating threads in accordance with the present invention; [35] FIG. 12A is a view illustrating a thread bundle A, B, D or E caught by a sinker upon knitting; [36] FIG. 12B is a view illustrating a thread bundle C caught by a sinker upon knitting; and [37] FIG. 13 is a configuration diagram of socks fabricated by the knitting machine in accordance with the present invention. [38]

Mode for the Invention [39] Now, a preferred embodiment of the present invention will be explained in detail with reference to the accompanying drawings. [40] FIGS. 1 and 2 are a perspective view and plan view, respectively, illustrating important parts of a knitting machine in accordance with the present invention. As shown, the knitting machine of the present invention includes a plurality of needles 1 and sinkers 2 for use in a knitting operation. Specifically, approximately two hundred needles 1 are arranged along an inner diameter portion of a cylinder 3 to reciprocally move in a vertical direction, and approximately the same number of sinkers 2 are interposed between the respective neighboring needles 1 at a right angle to the needles 1 in a horizontally movable manner. The configuration of the needles 1, sinkers 2 and cylinder 3 are equal to that of a conventional knitting machine.

[41] A weft thread guiding assembly 4A, a warp thread guiding assembly 4B, and first and second thread guiding assemblies 5A and 5B are arranged circumferentially on a top of the cylinder 3 above the needles 1 and sinkers 2. The weft thread guiding assembly 4A is used to guide a heating thread Hl as a weft thread, which is formed by coating a copper wire with an insulating material, and two or more general threads Y to predetermined ones of the needles 1 and sinkers 2. The warp thread guiding assembly 4B is used to guide a heating thread H2 as a warp thread and two or more general threads Y to predetermined ones of the needles 1 and sinkers 2. The first and second thread guiding assemblies 5A and 5B are used to guide two or more general threads Y to predetermined ones of the needles 1 and singers 2, respectively.

[42] The heating threads Hl and H2 and a plurality of strands of general threads Y to be guided and fed through the respective thread guiding assemblies 4A, 4B, 5 A and 5B are caught by predetermined ones of the sinkers 2 located at predetermined positions. Accordingly, if the cylinder 3 rotates, the plurality of needles 1 arranged in the cylinder 3 along a circumferential direction thereof are reciprocally moved in a vertical direction by a cam (not shown) so as to pull down the heating threads Hl and H2 and general threads Y caught by the sinkers 2, resulting in knitting of a fabric.

[43] The knitting machine of the present invention, as shown in FIG. 3, includes a tension regulating mechanism for regulating a tension of the heating thread Hl as the weft thread to be guided by the weft thread guiding assembly 4A. The tension regulating mechanism serves to prevent the heating thread Hl as the weft thread, which was fed through the weft thread guiding assembly 4A, from snapping by an excessive tension thereof when being woven by the needles 1 and sinkers 2. As shown in FIGS. 3 to 7, the heating thread tension regulating mechanism includes a feed reel 10, on which the heating thread Hl as the weft thread to be fed to the predetermined needle 1 and sinker 2 through the weft thread guiding assembly 4A is wound. The feed reel 10 is rotatably mounted to a sidewall of a table 6 of the knitting machine such that the center of the feed reel 10 is connected to a shaft 1 Ia of a step motor 11 so as to be rotated in accordance with operation of the step motor 11.

[44] To rotate the feed reel 10, a rotating speed of the step motor 11 can be reduced by a reduction gear row (not shown) received in a reduction gear box 1 Ib. The rotating speed of the step motor 11 is controlled by a controller 8 (See FIG. 4) that is received in a control box 7.

[45] The heating thread Hl as the weft thread, which is fed from the feed reel 10, is guided to the weft thread guiding assembly 4A by use of guide means. The guide means include a guide piece 12 having a guide hole for the passage of the heating thread Hl as the weft thread and a loop 13. The guide piece 12 is located at a side location of the table 6, and the loop 13 is located above the weft thread guiding assembly 4 while being supported by a feed tension sensing unit 40 that will be explained hereinafter. It should be understood that the configuration of the guide means is not limited to the above description, and other configurations are applicable so long as they guarantee efficient feeding of the heating thread Hl as the weft thread while guiding the heating thread Hl in a predetermined path.

[46] To control the rotating speed of the step motor 11, the knitting machine of the present invention includes an input device 20 for inputting a control signal to the controller 8. The input device 20, as shown in FIG. 4, includes a regulating switch 21, feed rate sensing unit 30 and feed tension sensing unit 40. The input device 20 can control the rotating speed of the step motor 11 by use of any one of the above constituent elements or various combinations thereof.

[47] Specifically, the regulating switch 21 is connected to the controller 8 and adapted to change a current or voltage to be applied to the step motor 11. Accordingly, by regulating the rotating speed of the step motor 11 through the operator s manual operation using the regulating switch 21 for changing the current or voltage, a feed rate and feed tension of the heating thread Hl as the weft thread can be regulated.

[48] The feed rate sensing unit 30 serves to detect an outer diameter of a winding of the heating thread Hl as the weft thread wound on the feed reel 10. The feed rate sensing unit 30 includes a detecting lever 32 and a rotating angle detecting sensor 33. The detecting lever 32 has one end rotatably installed to a bracket 31 and the other end adapted to come into continuous contact with an outer periphery of the winding of the heating thread Hl as the weft thread wound on the feed reel 10, thereby serving to detect the outer diameter of the winding of the heating thread Hl as the weft thread. The rotating angle detecting sensor 33 serves to detect a rotating angle of the detecting lever 32.

[49] Accordingly, the rotating angle detecting sensor 33 detects a variation in the outer diameter of the winding of the heating thread Hl as the weft thread wound on the feed reel 10 while the heating thread Hl as the weft thread is fed, and inputs a control signal to the controller 8. Based on the control signal, the controller 8 controls the rotating speed of the step motor 11 by calculating a difference in the outer diameter of the winding of the heating thread Hl as the weft thread, thereby regulating the feed rate and tension of the heating thread Hl as the weft thread.

[50] The feed tension sensing unit 40 serves to detect a tension of the heating thread Hl as the weft thread to be fed. The feed tension sensing unit 40 includes an oscillating lever 42 rotatably mounted on a fixed frame 41, an elastic wire 43 having one end secured to the oscillating lever 42 and the other end connected to the loop 13 that is used to guide the heating thread Hl as the weft thread to be fed, a touch sensor 44 mounted to the fixed frame 41 at a position adjacent to the oscillating lever 42, a touch bar 45 provided at the oscillating lever 42 and adapted to operate the touch sensor 44 in cooperation with the rotating oscillating lever 42, and an elastic member 46 installed between the oscillating lever 42 and the fixed frame 41, the elastic member 46 being made of a coil spring that maintains a tension of the heating thread Hl as the weft thread guided by the elastic wire 43 at a constant level.

[51] Accordingly, if a tension is generated in the heating thread Hl as the weft thread, the touch sensor 44 is operated by the elastic wire 43 and oscillating lever 42 cooperating with the heating thread Hl, thereby inputting a control signal to the controller 8. The controller 8 controls the rotating speed of the step motor 11 based on the control signal, thereby enabling the feed rate and feed tension of the heating thread Hl as the weft thread to be regulated.

[52] With the knitting machine having the above described configuration, the heating thread Hl as the weft thread and the heating thread H2 as the warp thread, which are formed by coating copper wires with an insulating material, can be fed to the predetermined needles 1 and sinkers 2 through the weft and warp thread guiding assemblies 4A and 4B. During feeding of the heating thread Hl, also, the tension regulating mechanism can prevent snapping of the heating thread Hl as the weft thread having less flexuous deformation ability. As a result, the knitting machine of the present invention has a function of knitting the heating threads Hl and H2 as the weft and warp threads with general threads.

[53] More specifically, in operation of the tension regulating mechanism for the heating thread Hl as the weft thread, as shown in FIGS. 3 and 8, if the knitting machine is turned on to operate the step motor 11 (Sl), the step motor 11 is rotated at a speed preset by the controller 8, thereby allowing the heating thread Hl as the weft to be transferred to the thread guiding assembly 4 A while being guided by the guide piece 12 and loop 13. Subsequently, the heating thread Hl as the weft thread is guided to the predetermined needle 1 and sinker 2 to be woven with other threads.

[54] In the course of guiding and feeding the heating thread Hl as the weft thread, if the feed rate of the heating thread Hl by the step motor 11 differs from a predetermined knitting rate, the heating thread Hl as the weft thread to be fed has a variation in tension thereof. Also, as the outer diameter of the winding of the heating thread Hl as the weft thread wound on the feed reel 10 decreases in accordance with the feeding of the heating thread Hl as the weft thread, the feed rate of the weft heating thread Hl decreases proportionally. Even in this case, similarly, the heating thread Hl as the weft thread has a variation in the feed rate and feed tension thereof. Accordingly, there is a necessity for continuously maintaining the feed rate and feed tension of the heating thread Hl at an appropriate level.

[55] For this, the controller 8 determines continuously whether or not the control signal is inputted from the input device 20 (S2). If the control signal is inputted, the controller 8 controls the rotating speed of the step motor 11, thereby regulating the tension of the heating thread Hl as the weft thread (S3).

[56] Specifically, as shown in FIG. 4, if the operator manually regulates the regulating switch 21 that is one of the constitute elements of the input device 20 connected to the controller 8, the control signal from the regulating switch 21 is inputted to the controller 8. The controller 8 determines continuously whether or not the input signal from the regulating switch 21 is inputted (S2). If the control signal is inputted, the controller 8 controls the current or voltage to be applied to the step motor 11, so as to regulate the rotating speed of the step motor 11 (S3). In this way, the feed tension and feed rate of the heating thread Hl as the weft thread can be regulated to an appropriate level.

[57] As shown in FIGS. 5 and 6, if the outer diameter of the winding of the heating thread Hl as the weft thread wound on the feed reel 10 decreases to a degree shown by a double dotted dashed line in accordance with the feeding of the heating thread Hl as the weft thread, the detecting lever 32 that comes into contact with the outer periphery of the winding of the heating thread Hl as the weft thread is rotated from a state shown by a solid line to a state shown by a double dotted dashed line. Thereby, the rotating angle detecting sensor 33 detects a difference in a rotating angle of the detecting lever

32 and inputs the detected result to the controller 8. Then, the controller 8 determines continuously whether or not the control signal from the rotating angle detecting sensor

33 is inputted (S2). If the control signal is inputted, the controller 8 regulates the rotating speed of the step motor 11 by calculating a variation in the outer diameter of the winding of the heating thread Hl, so as to maintain the feed rate of the heating thread Hl as the weft thread at a constant level (S3). In this way, the feed tension and feed rate of the heating thread Hl as the weft thread can be maintained at an appropriate level.

[58] As shown in FIG. 7, if an excessive tension is generated in the heating thread Hl as the weft thread, the elastic wire 43 connected to the loop 13 that guides the feeding of the heating thread Hl as the weft thread is moved from a state shown by a solid line to a state shown by a double dotted dashed line. Thereby, the oscillating lever 42 secured to the elastic wire 43 is rotated from a state shown by a solid line to a state shown by a double dotted dashed line. Subsequently, if the touch bar 45 provided at the oscillating lever 42 operates the touch sensor 44 in response to the rotation of the oscillating lever 42, a control signal from the touch sensor 44 is inputted to the controller 8. The control ler 8 determines continuously whether or not the control signal from the touch sensor 44 is inputted (S2). If the control signal is inputted, the controller 8 immediately increases the rotating speed of the step motor 11 (S3), so as to absorb the excessive tension of the heating thread Hl as the weft thread. If the heating thread Hl as the weft thread restores an original normal tension thereof as a result of the tension absorbing operation, the elastic wire 43 is returned to its original state shown by the solid line, and spaced apart from the touch sensor 44. Thereby, no control signal from the touch sensor 44 is inputted to the controller 8, and the controller 8 immediately decreases the rotating speed of the step motor 11 to an original rotating speed 8. In this way, the feed tension and feed rate of the heating thread Hl as the weft thread can be maintained at an appropriate level.

[59] In relation with the operation of the input device 20 as stated above, controlling the operation of the step motor 11 by the regulating switch 21 can be performed via the operator s manual operation whenever it is necessary, and controlling the operation of the step motor by the feed rate sensing unit 30 and feed tension sensing unit 40 can be automatically accomplished by repeatedly performing the above described control operation during the knitting of a fabric.

[60] Thereafter, the controller 8 determines continuously whether or not a power of the knitting machine is turned off (S4). If the power is turned off, the controller 8 stops the operation of the step motor 11 (S5), ending the operation of the knitting machine.

[61] The knitting machine of the present invention having the above described operation can prevent the heating thread Hl as the weft thread, which is formed by coating a conductive metallic wire, such as copper wire etc., by an insulating material and thus, has less flexuous deformation ability, from snapping due to excessive tension thereof during knitting of a fabric by virtue of the tension regulating mechanism thereof. As a result, the knitting machine of the present invention enables heating threads to be woven with general threads.

[62] Although the tension regulating mechanism of the present invention is shown and illustrated in relation with the heating thread Hl as the weft thread to be guided to the weft thread guiding assembly 4A, it should be understood that the tension regulating mechanism is also applicable to the heating thread H2 as the warp thread to be guided to the warp thread guiding assembly 4B, and can guide general threads having a high flexuous deformation ability, such as cotton thread, synthetic fiber threads, rubber threads, and the like, to conventional guide means.

[63] Now, a knitted fabric fabricated by use of the knitting machine of the present invention and a fabric knitting procedure will be explained with reference to FIGS. 1, 2, 9, 10, 11 and 12. FIGS. 9 and 10 are life-size photographs, respectively, illustrating the knitted structure of a knitted fabric including heating threads in accordance with the present invention, and a vertically pulled and spread state of the knitted structure. FIG. 11 illustrates a knitting procedure of the fabric. For the sake of explanation, it is assumed that the plurality of needles 1 are divided into an odd number group Ia and an even number group Ib, thread bundle A includes a strand of the heating thread Hl as the weft thread and general threads Y including two strands of cotton threads and a strand of rubber thread, which are guided to the weft thread guiding assembly 4a to be woven together, thread bundle B includes general threads Y including two strands of cotton threads to be guided to the first thread guiding assembly 5a to be woven together, thread bundle C includes general threads Y including three strands of cotton threads and a strand of rubber thread, which are guided to the warp thread guiding assembly 4B to be woven together, thread bundle D includes general threads Y including a strand of silver thread S, four strands of cotton threads, two strands of spandex thread and a strand of rubber thread to be guided to the second thread guiding assembly 5b to be woven together, and thread bundle E includes the heating thread H2 as the warp thread to be guided to the warp thread guiding assembly 4B.

[64] First, as shown in FIGS. 1 and 2, the thread bundle A is guided to the predetermined needle 1 and sinker 2 through the weft thread guiding assembly 4A, the thread bundle B is guided to the same needle 1 and sinker 2 as those of the thread bundle A through the first thread guiding assembly 5A to be woven with the thread bundle A. Also, the thread bundles C and E are guided to predetermined needles 1 and sinkers 2 different from each other, which are also different from those of the thread bundles A and B, through the warp thread guiding assembly 4B. The thread bundle D is guided to a predetermined needle 1 and sinker 2 different from those of the thread bundles A, B, C and E through the second thread guiding assembly 5B.

[65] As shown in FIG. 11, the thread bundle A is woven by use of the needles of the odd number group Ia except for the needles of the even number group Ib, so as to produce a first knitted structure AS including the heating thread Hl as the weft thread as shown in FIG. 10. The thread bundle B is woven with the thread bundle A by use of the needles of the even number group Ib, to produce a second knitted structure BS surrounding a part of the first knitted structure AS.

[66] The thread bundle C is woven by use of the needles of the odd number group Ib in a different manner from a conventional manner. Specifically, the thread bundles A, B, D and E are woven as the needles 1 are reciprocally moved in a vertical direction in a state wherein the thread bundles A, B, D and E are caught by holes 2a of the sinkers 2 as shown in FIG. 12A, whereas the thread bundle C is woven in a state wherein it is located on the sinker 2 rather than being caught by the hole 2a of the sinker 2 as shown in FIG. 12B. With this manner, a fourth knitted structure CS in which the thread bundle C protrudes from a surface of the resulting fabric as shown in FIG. 10 can be produced. The fourth knitted structure CS, as shown in FIG. 9, covers the first knitted structure AS including the heating thread Hl as the weft thread, thereby serving to prevent the heating thread Hl as the weft thread from being exposed to the outside from the surface of the resulting fabric.

[67] The thread bundle D is woven by use of all the needles of the odd and even number groups Ia and Ib, to produce a third knitted structure DS as shown in FIG. 10. The third knitted structure DS, as shown in FIG. 9, serves to space the neighboring first knitted structures AS apart from each other by a predetermined distance L. Although the present embodiment illustrates and describes that the thread bundle D is woven one time per one turn of the cylinder 3 to produce a single third knitted structure DS, it should be understood that a plurality of the thread bundles D may be fed per one turn of the cylinder 3 to produce a plurality of third knitted structures DS. This is efficient to regulate the distance L between the neighboring first knitted structures AS.

[68] The thread bundle E of the heating thread H2 as the warp thread is woven with the fourth knitted structure CS between the first knitted structure AS and the following first knitted structure AS by use of only one needle 1 selected from the odd or even number group, to produce a fifth knitted structure ES. The thread bundle E is woven in a direction at a right angle to the weaving direction of the thread bundles A to D.

[69] In this way, if the cylinder 3 rotates one turn starting from a knitting position of the thread bundle A, as shown in FIGS. 9 and 10, a set of the first to fifth knitted structures are produced, and a knitted fabric including the heating threads can be manufactured by repeatedly producing the set of knitted structures. The knitted fabric can be used in the manufacture of socks, gloves, muffler, cap and the like, and moreover, the manufactured clothes can be efficiently used as insulated clothes for cold environments by supplying power to the heating threads as the weft and warp threads.

[70] The second and fourth knitted structure BS and CS produced by the thread bundles

B and C, as shown in FIG. 9, cover the first knitted structure AS including the heating thread Hl as the weft thread, and therefore, have the effect of preventing the heating thread Hl as the weft thread from coming into direct contact with the human body. T his provides an improvement in wearing feeling of the manufactured clothes and eliminates the risk of peeling of the insulating coating or breaking of the wire due to frictional contact abrasion.

[71] The third knitted structure DS produced by the thread bundle D can maintain a constant distance L between the neighboring first knitted structures AS. Furthermore, when a plurality of the third knitted structures DS, for example two to six of third knitted structures DS are produced, the distance L between the neighboring first knitted structures AS including the heating threads Hl as the weft threads can increase. In this way, the amount of heat emitted from the heating threads per unit area and the overall heating area of the fabric can be regulated in accordance with the use purpose of clothes.

[72] The fifth knitted structure ES, which is produced by the thread bundle E is woven with the fourth knitted structure CS between the first knitted structure AS and the following knitted structure AS, serves to prevent movement of the first knitted structures AS, thereby maintaining the distance L between the neighboring first knitted structures AS. This consequently prevents the heating thread Hl as the weft thread from coming into contact with the heating thread H2 as the warp thread, thereby eliminating the risk of short circuit due to contact.

[73] FIG. 13 illustrates the configuration of insulated socks for cold environments fabricated by the knitting machine of the present invention. As a result of knitting the socks with the thread bundles A to E by use of the knitting machine of the present invention, the heating thread Hl as the weft thread is spirally arranged in sequence by a predetermined distance in a longitudinal direction of a sock body 101, and the heating thread H2 as the warp thread linearly extends along the longitudinal direction of the body 101.

[74] One end of the heating thread Hl as the weft thread is electrically connected to one end of the heating thread H2 as the warp thread at a position 102 of the body 101, and the other ends of the heating threads Hl and H2 are connected to a power supply device for supplying power to the heating threads Hl and H2. The power supply device includes a first terminal unit 103 provided at the body 101 to be electrically connected to the other ends of the heating threads Hl and H2 as the weft and warp threads, a second terminal unit 104 electrically connected to the first terminal unit 103 in a detachable manner, a power source 105 electrically connected to the second terminal unit 104 for supplying electric power, and a regulator 106 adapted to turn on and off the power source 105 or to regulate a voltage or current to be fed to the heating threads Hl and H2.

[75] The first terminal unit 103 includes an insulating terminal plate 103c attached to the body 101, and conductive terminals 103 a and 103b provided at the terminal plate 103c and each having a recess. The second terminal unit 104 includes an insulating terminal plate 104c and conductive terminals 104a and 104b provided at the terminal plate 104c and each having a protrusion to be detachably inserted into the associated recess. It should be understood that the configuration of the terminal units are not limited to the above description of the present embodiment, and other configurations are applicable so long as they are electrically connectable to and detachable from each other.

[76] When a portable battery is used as the power source 105, charging of electric power can be accomplished outdoors. Also, even when being charged indoors, a domestic alternating power source can be used after being converted as a low- voltage direct power source through the use of an adaptor.

[77] In the present invention, as shown in FIG. 1, furthermore, a silver thread S can be woven together with general threads during the weaving of the thread bundle D, and a plurality of small and thin bio-ceramic plates 107 may be attached to the bottom of the sock.

[78] With the sock having the above described configuration, if the power source 105 is turned on through the regulator 106, electric current is supplied from the power source 105 to the heating threads Hl and H2 as the weft and warp threads through the first and second terminal units 103 and 104, thereby allowing the heating threads Hl and H2 as the weft and warp threads to emit heat. As a result, the socks knitted by using the heating threads Hl and H2 can protect the user s feet against the cold. In this case, by regulating the feed current or voltage by the regulator 106, the heating temperature of the heating threads Hl and H2 can be freely regulated to a desired value.

[79] The silver thread S woven together with general threads has sterilization, antibacterial and deodorization functions by virtue of silver ions emitted therefrom, and the bio ceramic plates 107 attached to the bottom of the socks have antibacterial, deodorization and blood circulation promotion functions by virtue of emission of far- infrared rays.

[80] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. Industrial Applicability

[81] As apparent from the above description, the present invention provides a knitting machine including a weft thread guiding assembly and warp thread guiding assembly capable of feeding heating threads, which are formed by coating conductive metallic wires, such as copper wires, etc. with an insulating material, while automatically regulating a tension of the heating threads. The knitting machine of the present invention can prevent snapping of the heating threads, thereby enabling knitting of a fabric including the heating threads.

[82] Further, the knitted fabric including the heating threads fabricated by the knitting machine of the present invention can be used in the manufacture of insulated clothes for cold environments, such as for example, socks, gloves, vest, muffler, cap and the like.

Claims

[1] A knitting machine comprising a cylinder, a plurality of needles and sinkers arranged along an inner diameter portion of the cylinder, and thread guiding assemblies for guiding general threads to the needles and sinkers for the knitting of a fabric, further comprising: a weft thread guiding assembly for guiding a heating thread as a weft thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers; a warp thread guiding assembly for guiding a heating thread as a warp thread, which is formed by coating a copper wire with an insulating material, and two or more general threads to predetermined ones of the needles and sinkers; and a heating thread tension regulating mechanism for regulating a tension of the heating thread as the weft thread being guided to the weft thread guiding assembly.

[2] The knitting machine according to claim 1, wherein the tension regulating mechanism comprises: a rotatably installed feed reel on which the heating thread as the weft thread is wound; a step motor for rotating the feed reel; guide means for guiding the heating thread as the weft thread being fed from the feed reel to the weft thread guiding assembly; a controller for controlling a rotating speed of the step motor; and an input device for inputting a control signal to the controller.

[3] The knitting machine according to claim 2, wherein the input device comprises a regulating switch for changing a current or voltage to be applied to the step motor through the controller.

[4] The knitting machine according to claim 2, wherein the input device comprises a thread feed rate sensing unit for detecting an outer diameter of a winding of the thread wound on the feed reel.

[5] The knitting machine according to claim 2, wherein the input device comprises a feed tension sensing unit for detecting a tension of the thread to be fed.

[6] The knitting machine according to claim 4 or 5, wherein the input device further comprises a regulating switch for changing a current or voltage to be applied to the step motor through the controller.

[7] The knitting machine according to claim 5, wherein the input device further comprises a feed rate sensing unit for detecting an outer diameter of a winding of the thread wound on the feed reel.

[8] The knitting machine according to claim 7, wherein the input device further comprises a regulating switch for changing a current or voltage to be applied to the step motor through the controller.

[9] The knitting machine according to claim 4, wherein the feed rate sensing unit comprises: a detecting lever having one end rotatably installed to a bracket and the other end adapted to come into continuous contact with an outer periphery of the winding of the thread wound on the feed reel so as to detect an outer diameter of the winding; and a rotating angle detecting sensor for detecting a rotating angle of the detecting lever.

[10] The knitting machine according to claim 5, wherein the feed tension sensing unit comprises: an oscillating lever rotatably installed to a fixed frame; an elastic wire having one end secured to the oscillating lever and the other end for guiding the thread being fed; a touch sensor installed to the fixed frame at a position adjacent to the oscillating lever; a touch bar provided at the oscillating lever and adapted to operate the touch sensor in cooperation with a rotating motion of the oscillating lever; and an elastic member installed between the oscillating lever and the fixed frame and adapted to maintain a tension of the thread being guided by the elastic wire at a constant level.

[11] A knitted fabric comprising: a first knitted structure produced by knitting a heating thread as a weft thread and a plurality of strands of general threads by use of needles of an odd number group; a second knitted structure produced by knitting a plurality of strands of general threads by use of needles of an even number group at the same knitting position as that of the first knitted structure, the second knitted structure surrounding the first knitted structure; and a third knitted structure produced by knitting a plurality of strands of general threads by use of the needles of the odd and even number groups, the third knitting structure serving to maintain a predetermined distance between the neighboring first knitted structures, wherein the first to third knitted structures constitute a set of knitted structures obtained via a one-time operation, and the knitted fabric is fabricated by repeatedly producing the set of knitted structures.

[12] The knitted fabric according to claim 11, wherein the set of knitted structures obtained via a one-time operation further comprises a fourth knitted structure produced between the first knitted structure and the third knitted structure by knitting a plurality of strands of general threads by use of the needles of the odd number group, the fourth knitted structure covering the first knitted structure by allowing the general threads to protrude from a surface thereof.

[13] The knitted fabric according to claim 11 or 12, wherein the set of knitted structures obtained via a one-time operation further comprises a fifth knitted structure produced between the first knitted structure and the following knitted structure by knitting a heating thread as a warp thread by use of a selected one of the needles of the odd or even number group.

[14] The knitted fabric according to claim 11, wherein a plurality of third knitted structures are included in the set of knitted structures.

[15] The knitted fabric according to claim 11, wherein the general threads for use in the production of the third knitted structure include a silver thread.

[16] Socks fabricated by knitting general threads comprising: a heating thread as a weft thread spirally arranged in sequence by a predetermined distance in a longitudinal direction of a sock body; a heating thread as a warp thread arranged linearly along the longitudinal direction of the body and having one end electrically connected to one end of the heating thread as the weft thread; and a power supply device electrically connected to the other end of the heating thread as the weft thread and the other end of the heating thread as the warp thread and adapted to supply power to the heating threads as the weft and warp threads.

[17] The socks according to claim 16, wherein a plurality of thin bio ceramic plates are arranged on a bottom portion of the body.

[18] The socks according to claim 16 or 17, wherein the general threads for use in the production of the body include a silver thread.

[19] The socks according to claim 16, wherein the power supply device comprises: a first terminal unit provided on the body and electrically connected to the other ends of the heating threads as the weft and warp threads; a second terminal unit electrically connected to the first terminal unit in a detachable manner; a power source electrically connected to the second terminal unit and adapted to supply power; and a regulator for regulating a voltage or current supplied from the power source.

[20] The socks according to claim 19, wherein the first terminal unit comprises an insulating terminal plate attached to the body and conductive terminals arranged on the terminal plate and each having a recess, and the second terminal unit comprises an insulating terminal plate and conductive terminals arranged on the terminal plate and each having a protrusion to be detachably inserted into the associated recess.