Method to produce a double selection fabric

Applicant: Bekaertdeslee Innovation
Inventor(s): Jürgen Andreas KUNZMANN & Kara W. PRUITT
Patent number: EP4417742A1
Publication date: 2024-08-21

A double selection fabric (also known as a double jersey knit fabric or wear) is a traditional knit fabric that is produced using a circular knitting machine. This machine is equipped with a cylinder and a dial (positioned just above the cylinder), each containing needles. The needles on the cylinder are typically used for knitting the front of the fabric, while the needles on the dial are typically used for knitting the back of the fabric.

In a double selection circular knitting machine, the needles of the cylinder and the dial are independently driven by an electronic pattern mechanism, through which every single needle of the cylinder/dial can be selected to either knit, miss or tuck. This enables the production of a design on the front and the back of the fabric.

It is common practice to add lay-in yarns between the dial and cylinder in order to create volume in double jersey knit fabrics, for example when used as mattress ticking. In areas where the front and back are not knitted together, known as blister zones, the inlay yarn present throughout the fabric will create a voluminous appearance.

It is worth noting that the inlay yarn, which is permanently laid in between the back and front layers, can present limitations in creating flat or deep areas. If the flat areas are too large, the inlay yarn will push through the front layer, creating defects known as 'popping out inlay'. Furthermore, the current design allows for only one colour of inlay yarn, either white or dyed.

The aim is to address the limitations of the current method by proposing a new approach to creating double selection fabrics with multiple blister zones and varying appearances.

To address the previously mentioned limitations, the invention offers techniques for producing a double selection fabric that reduces fabric defects and creates a fabric with multiple blister zones of varying appearances.

In one embodiment, a method is provided to produce a double selection fabric comprising a back and a front layer and at least a first and a second blister zone with different properties. The method comprises the use of at least a first and a second different inlay yarn, wherein the first blister zone is created by inserting the first inlay yarn between the back and front layers of the double selection fabric, while the second inlay yarn is knitted to the back layer. The second blister zone is formed by inserting the second inlay yarn between the back and front layers of the double selection fabric, with the first inlay yarn knitted to the back layer. Finally, the first and second inlay yarns are knitted to the back layer of the double selection fabric, extending beyond the aforementioned first and second blister zones.

Another embodiment provides a double selection fabric comprising a back and a front layer and at least a first and a second blister zone of different properties. 

• In the first blister zone, a first inlay yarn is positioned between the back and front layers of the double selection fabric, with a second, different inlay yarn knitted to the back layer.
• In the second blister zone, the second, different inlay yarn is positioned between the back and front layers of the double selection fabric, with the first inlay yarn knitted to the back layer.
• The first and second, different inlay yarns are knitted to the back layer of the double selection fabric, outside of the at least first and second blister zones.

The above figure illustrates the popping of the inlay in the flat areas using the prior art method, as well as the lack of popping in the flat areas using the method of the present disclosure.