WO2008009971A2

WO2008009971A2 - Glove knitting techniques

Info

Publication number: WO2008009971A2
Application number: PCT/GB2007/002791
Authority: WO
Inventors: Tilak Dias; William Hunter; Kimberley Mitcham
Original assignee: Engineered Fibre Structures Limited
Priority date: 2006-07-20
Filing date: 2007-07-20
Publication date: 2008-01-24
Also published as: WO2008009971A3; GB0614383D0

Abstract

A method for knitting gloves is disclosed, in which successive courses are knitted parallel to the main glove axis (along the line of the middle finger). The first row of stitches is formed along the line of either the smallest finger or the thumb, and the process is continued to successively form all five digits, integral with the core section. The fingers and thumb are knitted as parallel tubular elements, but the glove as a whole can be shaped to match different hand contours.

Description

GLOVE KNITTING TECHNIQUES

This invention relates to knitting techniques and particularly to such techniques applied to gloves. The knitting of a glove in a continuous process creates particular problems because of the need to knit and merge four fingers and a thumb into a main core section.

The present invention is directed at the knitting of a glove on a flat-bed knitting machine.

A typical electronic flat-bed knitting machine has precisely engineered needle beds made out of flat hardened steel plates. On industrial flat-bed knitting machines a minimum of two such needle beds are arranged in an inverted V-form. In the needle beds, generally latch needles are placed inside needle tricks (open rectangular grooves precisely cut to accommodate needles) on the top surface of the needle bed. The above assembly guarantees the movement of needles individually and axially during the knitting process. A system of linear cams moves the needles between two dead centres in order to form stitches. The use of the needle-latch to open and close the needle hook area of a latch needle simplifies the stitch formation process. This combination of needle tricks and latch needles enables the creation of complex 3-D structures on these machines. The utilisation of two needle beds also provides two needle systems with the freedom of movement in two independent planes; thus providing the basis for forming stitches in three dimensional space.

In accordance with one method of the invention for knitting gloves on such a machine, successive courses are knitted parallel to the main glove axis (along the line of the middle finger). The first row of stitches is normally formed along the line of the smallest finger, with the process continuing to successively form the four fingers and the thumb, with the core section. In this technique the fingers and thumb are knitted as parallel tubular elements, but the glove can be shaped to match the normal shape of a human hand. The method can be adapted to match different hand shapes.

The above method can perhaps best be defined as a sequence of steps in the knitting of a glove having fingers and a thumb each with proximal and distal ends, on a flat bed knitting machine having front and back needle beds. The glove has a main axis generally parallel to the fingers of the glove, the method comprising the following steps. (a) knitting courses of stitches parallel to said axis alternately on the front and back needle base to form a first channel section; closing an end part of and an adjacent length of the channel to form a first finger and a first core section;

(b) continuing to knit to extend the first core section into a second core section; simultaneously knitting a second channel section adjacent the first finger; and closing the end and an adjacent length of the second channel section to form a second finger;

(c) repeating step (b) twice to form third and fourth fingers; and then third and fourth core sections;

(d) continuing to knit a fifth channel section and closing an end an adjacent length thereof is from the thumb; and

(e) closing the fourth core section and merging the closure with the closure of the fifth channel section.

In the above method, the first row of stitches knitted in step (a) is on one of the front and back needle beds. Subsequent rows are typically knitted in pairs alternately on each bed. The ends of the channel sections may be closed by continuing knitting with the same yarn carrier from one needle bed to the other. The formation of each finger can be completed by binding of the requisite length of each channel section from its distal to its proximal end.

According to another aspect of the present invention, a method is provided of knitting a glove on a flat-bed knitting machine, in which each finger is knitted from its distal to its proximal end, with the proximal ends then linked to form a core section. The fingers can be knitted using a "C-knitting" process or an alternative known as "tubular knitting". The thumb may also be knitted using a C-knitting process with the core section merging with the proximal end of the thumb, and being continued to complete the glove. By using a C-knitting process for the thumb in this method, the overall shape of the glove can be more readily adapted to the natural shape of the human hand. If desired, a wedge can be knitted into the core section at the proximal ends of the fingers to further facilitate this adaptation.

In the methods of the invention the initial rows of knitting in each finger and thumb will normally form a closed distal end. However, it will be appreciated that a so-called "fingerless" glove can readily be formed by leaving the finger and thumb distal ends open.

Known dimensional shaping techniques, such as course shaping, can be used to give the fingers and thumb of a glove made using the method of the invention a natural orientation. Similarly, the thickness of each finger and thumb can be varied along its length. It is also possible to use different yams within different sections of the glove using the known intarsia technique. This enables non-stretchable yarns to be used in some sections of the glove in combination with stretchable yarns in other sections to provide strength where needed, and elasticity in other areas. It is of particular value in the knitting of specialist gloves where durability or cut-resistance is required in particular, areas, but less so or not in others. More durable or cut- resistant yarns which are normally inherently less stretchable, can be used as required with elastomeric yarns elsewhere to facilitate the fitting of the glove to a hand.

Gloves made by methods of the invention may be formed with sections comprising conductive yarns with conductors connected to those yarns. Such a section can thus form a transducer, and such a transducer can be adapted either to respond to the delivery of electrical current to generate heat or light, or to generate an electrical signal in response to some change in the physical characteristic of the transducer, for transmission via the conductors. The section or sections can be knitted and is/are preferably integral with the structure of the glove. When receiving power, the transducer can act as a heater or signal mechanism. When acting as a transmitter it can respond to temperature changes, moisture levels, and mechanical distortion. In this last respect, reference is directed to International patent publication no. WO2004/100784, the disclosure whereof is hereby incorporated by reference. Use of conductive yarns in a knitted structure to form a heating element is described in British Patent Specification no. 2 417 660, the disclosure whereof is also hereby incorporated by reference.

Where conductive yarns are used in the knitting process to create a glove section of the kind described above, steps can be taken to protect the yarns from excessive distortion or extension. This can be accomplished by providing the requisite conductivity in at least one filament of a multi filament yarn, with at least one other filament being of a suitable material that has a higher modulus of elasticity than that of the conductive filament or filaments. The likelihood of excessive distortion can also be reduced by knitting the conductive yarns, in whatever form, with alternate needles in order to reduce the total number of contact points between the yarn and the knitting elements. Conductive yarns used in these variants of the invention can be silver thread; silver coated elastomeric yarn or carbon loaded polymeric yarns such as carbon loaded silicon yarns. Particularly where carbon loaded yarns are used, the protective mechanisms referred to above are recommended.

Conductors for carrying electrical power or signals to or from conductive yarns in a glove section of the kind referred to above can also be integrated within the knitted structure. They will normally extend within the structure in a direction substantially parallel to the main axis of the glove. Where the knitting is conducted in a direction parallel to the axis, this has the advantage that the same yarn feeder can be used to knit a plurality of separate conductors seriatim into the glove fabric.

The invention will now be described by way of example, and with reference to the accompanying schematic drawings wherein;

Figure 1 shows an overview of a glove and the component yarns used in its knitting according to one method according to the invention;

Figure 2 shows a plan view for illustrating an alternative method of the invention;

Figure 3 shows a plan view of a glove in which sections have been formed with conductive yams;

Figure 4 shows an enlarged view of a glove section forming a transducer; and

Figure 5 shows the back of a glove made according to the invention and including transducer sections in the digits.

The glove illustrated in the overview of Figure 1 is knitted progressively from the fingers to the wrist. After knitting waste fabric to the takedown rollers, a draw thread is introduced to be able to separate the waste fabric from the glove when the knitting is completed.

The knitting of each of the fingers 1 , 2, 3 and 4 Is perpendicular to the glove axis A, and starts in the same way. The yarn feeder (not shown) knits from the right hand side on empty needles (picking up). Between the first and second row of the stitches there are transfers which use the draw thread to lock down the first row of stitches. The second row is knitted from the left to the right. This is to enable the second row to be locked by the third row and facilitate the finishing of the glove when the knitting is completed, merely by pulling on loose ends of yarn. When the third row is knitted the closed distal end of the finger is finished closed.

The above procedure is carried out for the fingers 2, 3 and 4, and this can be carried out substantially simultaneously. A separate yarn feeder is used to knit each finger 1 , 2, 3 and 4. During at least the initial parts of this stage, two waste yarns are knitted in preparation for knitting the smallest finger 1, and the thumb 5. As the fingers are knitted, the length of the knitted courses as well as both of the needle beds can be varied in length to dimensionally shape the finger to conform with that of a human finger.

As noted above, the fingers are knitted using a tubular knitting process with each course of stitches being knitted one on the front and one on the back needle bed. As the knitting of fingers 2, 3 and 4 continues, waste yarns are transferred to the rear needle bed ready for use in knitting the smallest finger; finger 1. This is initiated in the same way as the other fingers, and as this finger is completed, preparations are made to knit a thumb 5. The yarns used to knit finger 2 are knitted across the same area as finger 1. This allows the yarn to be locked at a following stage, and once again to minimise the number of loose ends of yarn to contend with when the process is completed. The same procedure can be adopted for other adjacent fingers.

The yarn used to knit finger 4 is locked into the fabric at the proximal end, and the yam knitted out to the left hand side as shown is cast off. There are then, two courses of waste yarn and two course of draw thread knitted. The yarn feeder used to knit the finger 4 can now be used for the thumb 5, and as for the fingers, the first and second courses are used to lock the yarn at the welt of the thumb 5. The thumb 5 is now knitted using a C-knitting process, knitting alternately on the front and rear needle beds. Dimensional shaping is accomplished by varying the length of the respective courses.

The yarn feeder used to knit the finger 3 is used in the embodiment described to start knitting the core section of the glove and particularly the knuckle area. This area can also be dimensionally shaped enabling the angle at the proximal end of the fingers to be altered. At this stage a wedge can also be formed to align the proximal ends of the fingers with the normal shape of a human hand. The glove illustrated in Figure 2 is knitted parallel to the main glove axis A. A first row of stitches is knitted along the line of the smallest finger; finger 1, from right to left as indicated, on the front needle bed of a flat bed knitting machine. The second and third courses (rows) are knitted on the back needle bed using the same carrier from left to right and then right to left. The fourth and fifth courses are knitted similarly on the front needle bed, and these steps are repeated until sufficient fabric has been created to complete the first finger and the adjacent section 6 of the core or main body of the glove. This knitting process closes the distal end of the finger 1 , and the adjacent length 8 of the channel section is closed with a binding yarn. The channel in the core section 6 is of course left open.

The next finger 2 is knitted in the same way as finger 1 , and the process is repeated for the third and fourth (index) fingers creating core sections 6, 10, 12 and 14. The thumb 5 is knitted in the same way, but closure of the open side 16 of the respective channel section is merged with closure of last core section 14 to complete the glove. As in the glove of Figure 1 , dimensional shaping of the fingers, thumb and core section of Figure 2 can be accomplished by varying the length of the courses and the stitch lengths.

As the core section of the glove is knitted, different yarns can be introduced to create portions of one or both sides of the core section having different characteristics. Particularly, when the yarn used for the bulk of the glove, and particularly the fingers and thumb, is relatively inflexible, there is a clear benefit in using elastomeric yarns for at least one section of the glove to facilitate fitting the glove over a hand. At this stage, knitting of the core section can best be accomplished using a C-knitting process, with patches using different yarns being introduced using the intarsia technique. Inserts of stretchable portions can extend all the way to the wrist of the glove.

The above knitting methods can be applied to any glove, but have particular application where durable or cut-resistant yarns must be used for some areas of a glove that are particularly exposed during use but where some resilient elasticity is also required. The technique also enables stitch density to be varied in different areas of the glove as shown at 18 in Figure 1.

In Figure 3, the glove is formed with a number of identifiable sections 20 and 22. The sections 20 are located on the fingers and thumb. The section 22 is located in the palm or on the back of the hand. Conductors 24, 26 connect the respective sections to bus bar 28. Only one bus bar is shown in Figure 3. The other is on the other side of the glove and as can be seen, the conductors 26 from the sections in the fingers and thumb extend away from the wrist section and will pass over the extremity of the respective digits and on the other side of the glove to a corresponding bus bar.

Each section 20, 22 will normally be a transducer adapted to perform a particular function. As transmitters they can monitor distortion, temperature or moisture content for example, at a zone in which the glove is used. They can also function as heating elements, as noted above. In all these embodiments the bus bars 28 can of course be connected to either or both of a source of electrical power and a signal processor, depending on the purpose to which the conductive yarn sections are being put.

Figure 4 shows in more detail a section 20 of a glove finger in a form that could function as a sensor or electrode, monitoring changes in electrical characteristics and transmitting signals indicative or representative of such changes along conductors 24, 26. Conductive yarns 30 are knitted into the structure of the section 20 with the non-conductive yarns that form the glove fabric. The same conductive yarn extends from the section to form the conductors 24, 26. The section 20 shown might also function as a heater of the kind disclosed in British Patent Specification No. 2 417 660 referred to above, in which case it might be located in the palm of the glove, as shown at 22 in Figure 3. An alternative form of section 20 is shown in Figure 5. These extend the full length of the fingers and thumb of the glove, and are adapted particularly but not exclusively to act as heaters. Conductors 24, 26 connect the section to a source of electric power (not shown), typically via bus bars of the kind described above with reference to Figure 3. The sections themselves are knitted with alternate rows of conductive (30) and non-conductive yarns 32. The conductive yarns are multi-filament yams of which at least one filament comprises a conductive material such as silver or carbon loaded silicon, and at least one other filament is of a non-conductive polymeric material such as polyester, with a modulus of elasticity greater than that of the filament(s) comprising the conductive material. The conductive yarns are connected in parallel between the conductors 24 and 26, and are spaced from each other by the alternate non-conductive yarns 32 to avoid short circuits.

The reason for using multi-filament conductive yarns as described above is to minimize the stretch of the yarns during knitting. In a typical weft knitting process a row of stitches (course) is formed from the same yarn. This is achieved by laying the same yam over the hooks of the needles during the stitch formation process. Due to the construction of knitting cams several needles; for example 3-6, would be forming stitches with the same yarn at any given time; this results in a dynamic yarn tension build-up in the knitting zone. Theoretical analysis demonstrates that the above tension build-up follows an exponential function, which has been confirmed in various research projects. A problem with conductive elastomeric yarn is that in the above process it would stretch during knitting, which could result in an undefinable increase of its electrical resistance. In some cases we have found that silicone yarns exhibit plastic defomation. We can address this problem in a number of ways. One is to knit the conductive elastomeric yarn with a second yarn of a higher modulus to reduce the risk of excessive stretching, Another is to reduce the number of needles with which the yarn would come into contact in the knitting zone, by knitting at every second needle.

Claims

1. A method of knitting a glove having fingers and a thumb with proximal and distal ends, on a flat bed knitting machine having a front and back needle bed, which glove has a main axis generally parallel to the fingers of the glove, the method comprising

(a) knitting courses of stitches parallel to said axis alternately on the front and back needle bed to form a first channel section; closing an end and an adjacent length of the channel to form a first finger and a first core section;

(e) closing the fourth core section and merging said closure with the closure of the fifth channel section.

2. A method according to Claim 1 wherein the first row of stitches knitted in step (a) is on one of the front and back needle beds, and subsequent rows are knitted in pairs alternately on each bed.

3. A method according to Claim 1 or Claim 2 wherein closure of the ends of the channel sections is accomplished by continuing knitting with the same yarn carrier from one needle bed to the other.

4. A method according to any preceding Claim wherein the each length of channel section is closed to form a finger by binding off the requisite length.

5. A method according to any preceding Claim including the step of knitting a wedge in the core sections of the glove at the proximal end of the fingers.

6. A method according to any preceding Glaim wherein at least one of the fingers and thumb is dimensionally shaped.

7. A method according to any preceding Claim wherein a portion of one side of the core section is knitted using yarn different from that used elsewhere and in the fingers and thumb.

8. A method according to Claim 7 wherein said one side is in the palm side of the glove.

9. A method according to Claim 7 or Claim 8 wherein the portion is knitted using elastomeric yarns.

10. A method according to any preceding Claim wherein a section of the glove is knitted with conductive yams with conductors connected thereto.

11. A method according to Claim 10 wherein the section forms a transducer.

12. A method according to Claim 11 wherein the transducer is adapted to generate heat or light in response to a voltage applied via the connectors.

13. A method according to Claim 11 wherein the transducer is adapted to generate an electrical signal in response to a change in a physical characteristic, for transmission via the conductors.

14. A method according to any of Claims 10 to 13 wherein the conductive yarns in said section are multi-filament yarns in which at least one filament is conductive and at least one other filament is of a non-conductive material and has a higher modulus of elasticity than that of said at least one conductive filament.

15. A method according to any of Claims 10 to 14 wherein the conductive yarns are knitted with alternate needles.

16. A method according to any of Claims 10 to 15 wherein the conductors are conductive yarns forming part of the knitted structure.

17. A method according to Claim 16 wherein the conductors extend within the structure in a direction substantially parallel to the main axis of the glove.

18. A method of knitting a glove having fingers and a thumb on a flat-bed knitting machine, comprising knitting each finger from its distal to its proximal end; linking the proximal ends to form a core section; knitting the thumb using a C-knitting process; merging the core section with the proximal end of the thumb; and continuing to- knit the core section to complete the glove.

19. A method according to Claim 18 wherein each finger is knitted using a tubular knitting process.

20. A method according to Claim 18 or Claim 19 wherein a different yarn feeder is used to knit each finger.

21. A method according to any of Claims 18 to 20 wherein knitting of two adjacent fingers is at least in part simultaneous.

22. A method according to any of Claims 18 to 21 wherein the yarn feeder used to knit the thumb is that used to knit the adjacent finger.

23. A method according to any of Claims 18 to 22 wherein the initial rows of knitting in each finger form a closed distal end.