The development of a novel high speed fabric manufacturing process

The manufacture of conventional textiles usually involves either weaving or knitting. The author and his colleagues have devised a completely new technology for textile fabric construction involving the use of simple elements. These elements are basically similar in shape to sewing machine needles which interact with each other in such a way that yarns 'stitch-knit' themselves together to produce a fabric. As a result of this unique interaction the number of loops produced is doubled when compared to the time cycle of a conventional knitting action. Further enhancement of at least doubled fabric production rates should accrue from the dual effects of decreased yarn tensions and the lowered dynamic disturbing forces of the simplified knitting element manipulating system. A survey has been made of the looped-type textile manufacturing processes and the most appropriate groups have been enumerated in order to form a basis of comparison for the novel process. A basic study (including computer aided graphics) of probable textile structures, that could be produced by this technology, has revealed a substantial range of novel fabrics. These fabrics have been analysed and possible uses for them are suggested. A powered research-rig has been designed and constructed on which the important yarn manipulation characteristics have been determined. This experimentation has facilitated a more positive yarn pick-up to be evolved. As a result of this, more practicable design tolerances may be given for the manufacture and setting-up of the manipulative elements. Moreover, narrow-width novel fabric samples have been produced from spun-staple yarns at rates exceeding the current commercially available maximum, thereby substantiating the earlier predictions. Finally, the new technology and its resulting products are appraised and design proposals for a prototype machine are made; it is hoped that this will be offered to industry in due course for further development and potential exploitation.