Patent ID: 12195894

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The detailed description and technical content of the invention are described below with reference to the drawings.

Please refer toFIG.1andFIG.2. The invention provides a knitted fabric10with leather fibers. The knitted fabric10can be used to manufacture a garment, a shoe or a bag. The knitted fabric10is basically double knitted by a flat knitting machine (not shown in the figures). In addition, the knitted fabric10includes a ground yarn layer11and a face yarn layer12. The ground yarn layer11includes a plurality of first yarn loops111, and each of the first yarn loops111is formed with a plurality of ground yarns112. The face yarn layer12is directly connected to the ground yarn layer11through double knitting. Double knitting is well-known for those skilled in the art and will not be described herein. In addition, the face yarn layer12includes a plurality of second yarn loops121, and each of the second yarn loops121is formed with at least one face yarn123attached with a plurality of leather fibers122. Further, the plurality of leather fibers122is obtained from a piece of leather by a pulverization operation, and the leather can be a new product or a recycled waste product. The pulverization operation refers to cutting the leather through machinery, and the leather is cut from an original sheet shape into scraps to form the plurality of leather fibers122. In addition, sizes of the plurality of leather fibers122are not limited to be the same, and thicknesses of the plurality of leather fibers122are in a range between 0.5 mm and 2 mm. Furthermore, the at least one face yarn123includes the plurality of leather fibers122as well as a base yarn124to carry the plurality of leather fibers122. The base yarn124can be selected from different yarns according to implementation requirements which will not be described herein. In one embodiment, the base yarn124is made of thermoplastic polyurethane (TPU), which is obtained from recycling wastes with the thermoplastic polyurethane. In addition to the foregoing embodiment, the base yarn124can also be made of other environmentally friendly materials. Furthermore, a manufacturing process of the at least one face yarn123provides as follows. After the plurality of leather fibers122is obtained, the plurality of leather fibers122is added to liquid polyurethane (PU) to make a leather slurry, and then the base yarn124is placed into the leather slurry with the plurality of leather fibers122, so that the plurality of leather fibers122and the liquid polyurethane are wrapped around a surface of the base yarn124. Subsequently, the base yarn124wrapped with the leather slurry is taken out and baking in an appropriate time to form the at least one face yarn123. At this time, the at least one face yarn123is composed of the base yarn124and a polyurethane layer125, which is wrapped around an outer surface of the base yarn124and comprises the plurality of leather fibers122. The aforementioned baking step aims to remove moisture in the at least one face yarn123.

Considering that the at least one face yarn123contains the plurality of leather fibers122with different sizes, a problem of poor strength and a risk of being easily damaged would occur, if fabrics knitted by the at least one face yarn123thereof. In order to solve the above problems, the ground yarn layer11aims to strengthen the structure of the face yarn layer12except for being a backside of the knitted fabric10. Therefore, a course ratio of the face yarn layer12to the ground yarn layer11is in a range between 1:1.25 and 1:4, and a yarn tension of the at least one face yarn123is less than a yarn tension of the plurality of ground yarns112when the flat knitting machine is knitting. As shown inFIG.1for a schematic diagram of structure of the knitted fabric10, numbers of courses of the ground yarn layer11is more than numbers of courses of the face yarn layer12. That is to say, numbers of the first yarn loops111is more than numbers of the second yarn loops121. Under the condition that lengths of the ground yarn layer11and the face yarn layer12are the same, a yarn loop density of the ground yarn layer11is greater than a yarn loop density of the face yarn layer12. Here, a stronger knitting structure is formed to solve the problem of poor strength of the face yarn layer12.

Furthermore, in the invention, the connection between the ground yarn layer11and the face yarn layer12is not limited to a specific knitting structure to form the knitted fabric10. As shown inFIG.1, when two needle beds of the flat knitting machine are knitting, except for the at least one face yarn123, at least one of the plurality of ground yarns112is further fed to one of the two needle beds for knitting the face yarn layer12. Thus, the at least one of the plurality of ground yarns112not only forms the plurality of first yarn loops111, but also cooperates with the at least one face yarn123to form the plurality of second yarn loops121, thereby the ground yarn layer11and the face yarn layer12are connected realized by the at least one of the plurality of ground yarns112. In another embodiment as shown inFIG.3, after one part of the plurality of first yarn loops111is knitted by the other one of the two needle beds for knitting the ground yarn layer11, at least one of the plurality of ground yarns112and the at least one face yarn123are together fed to the needle bed for knitting the ground yarn layer11to knit another part of the plurality of first yarn loops111. Then, the at least one of the plurality of ground yarns112and the at least one face yarn123are together fed to the needle bed for knitting the face yarn layer12, whereby the connection between the ground yarn layer11and the face yarn layer12are realized by the at least one face yarn123and the at least one of the plurality of ground yarns112. Please refer to another embodiment inFIG.4. The at least one face yarn123is further fed to the needle bed for knitting the ground yarn layer11in one of knitting strokes, thus the ground yarn layer11and the face yarn layer12are connected realized by the at least one face yarn123.

Accordingly, please refer toFIG.5,FIG.6,FIG.7,FIG.8,FIG.9,FIG.10,FIG.11,FIG.12,FIG.13,FIG.14,FIG.15,FIG.16,FIG.17,FIG.18,FIG.19,FIG.20,FIG.21,FIG.22,FIG.23, FIG.24, andFIG.25, which show simplified knitting of two needle beds40,41of the flat knitting machine to meet the requirements that a course ratio of the face yarn layer12to the ground yarn layer11is in a range between 1:1.25 and 1:4. A structure of the two needle beds40,41of the flat knitting machine is well-known in the technical field, so that knitting needles mentioned in the following description have no drawings and referenced numerals.FIG.5is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.25. Precisely, the course ratio is written as 1:1+(1/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle of every four knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.5, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.25 times a yarn tension of the plurality of ground yarns112.

FIG.6is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.33, which is an approximate value. Precisely, the course ratio is written as 1:1+(1/3). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle of every three knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.6, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.33 times a yarn tension of the plurality of ground yarns112.

FIG.7is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.5. Precisely, the course ratio is written as 1:1+(1/2). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle of every two knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.7, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.5 times a yarn tension of the plurality of ground yarns112.

FIG.8is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.5. Precisely, the course ratio is written as 1:1+(2/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle and a second knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.8, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.5 times a yarn tension of the plurality of ground yarns112.

FIG.9is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.67, which an approximate value. Precisely, the course ratio is written as 1:1+(2/3). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle and a second knitting needle of every three knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.9, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.67 times a yarn tension of the plurality of ground yarns112.

FIG.10is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:1.75. Precisely, the course ratio is written as 1:1+(3/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, each knitting needle of the needle bed41for knitting the ground yarn layer11stitches one of the plurality of ground yarns112once, and a first knitting needle, a second knitting needle, and a third knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.10, a yarn tension of the at least one face yarn123is preferably set as approximately 1/1.75 times a yarn tension of the plurality of ground yarns112.

FIG.11is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2. In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11. Here, in practical knitting and feeding of the embodiment ofFIG.11, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2 times a yarn tension of the plurality of ground yarns112.

FIG.12is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.25. Precisely, the course ratio is written as 1:2+(1/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every four knitting needles thereof further stitches one of the ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.12, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.25 times a yarn tension of the plurality of ground yarns112.

FIG.13is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.33, which is an approximate value. Precisely, the course ratio is written as 1:2+(1/3). In one stroke, each knitting needle of the needle bed40for knit the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every three knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.13, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.33 times a yarn tension of the plurality of ground yarns112.

FIG.14is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.5. Precisely, the course ratio is written as 1:2+(1/2). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every two knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.14, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.5 times a yarn tension of the plurality of ground yarns112.

FIG.15is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.5. Precisely, the course ratio is written as 1:2+(2/4). In one stroke, each knitting needle for the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle and a second knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.15, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.5 times a yarn tension of the plurality of ground yarns112.

FIG.16is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.67, which is an approximate value. Precisely, the course ratio is written as 1:2+(2/3). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle and a second knitting needle of every three knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.16, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.67 times a yarn tension of the plurality of ground yarns112.

FIG.17is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:2.75. Precisely, the course ratio is written as 1:2+(3/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, two of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle, a second knitting needle, and a third knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.17, a yarn tension of the at least one face yarn123is preferably set as approximately 1/2.75 times a yarn tension of the plurality of ground yarns112.

FIG.18is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3. In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11. Here, in practical knitting and feeding of the embodiment ofFIG.18, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3 times a yarn tension of the plurality of ground yarns112.

FIG.19is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.25. Precisely, the course ratio is written as 1:3+(1/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every four knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.19, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.25 times a yarn tension of the plurality of ground yarns112.

FIG.20is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.33, which is an approximate value. Precisely, the course ratio is written as 1:3+(1/3). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every three knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.20, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.33 times a yarn tension of the plurality of ground yarns112.

FIG.21is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.5. Precisely, the course ratio is written as 1:3+(1/2). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle of every two knitting needles thereof further stitches one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.21, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.5 times a yarn tension of the plurality of ground yarns112.

FIG.22is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.5. Precisely, the course ratio is written as 1:3+(2/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle and a second knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.22, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.5 times a yarn tension of the plurality of ground yarns112.

FIG.23is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.67, which is an approximate value. Precisely, the course ratio is written as 1:3+(2/3). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle and a second knitting needle of every three knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.23, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.67 times a yarn tension of the plurality of ground yarns112.

FIG.24is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:3.75. Precisely, the course ratio is written as 1:3+(3/4). In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, three of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11, and a first knitting needle, a second knitting needle, and a third knitting needle of every four knitting needles thereof further stitch one of the plurality of ground yarns112again. Here, in practical knitting and feeding of the embodiment ofFIG.24, a yarn tension of the at least one face yarn123is preferably set as approximately 1/3.75 times a yarn tension of the plurality of ground yarns112.

FIG.25is a schematic diagram of one embodiment that a course ratio of the face yarn layer12to the ground yarn layer11is 1:4. In one stroke, each knitting needle of the needle bed40for knitting the face yarn layer12stitches the at least one face yarn123once; and in the same stroke, four of the plurality of ground yarns112are separately stitched once by each knitting needle of the needle bed41for knitting the ground yarn layer11. Here, in practical knitting and feeding of the embodiment ofFIG.25, a yarn tension of the at least one face yarn123is preferably set as approximately 1/4 times a yarn tension of the plurality of ground yarns112.

Please refer toFIG.1andFIG.26, a manufacturing method20for the knitted fabric10of the invention comprises following steps of:step A21: double knitting the plurality of ground yarns112and the at least one face yarn123by the flat knitting machine to form the knitted fabric10; andstep B22: ironing the knitted fabric10.

The invention avoids fabric curling caused by differences in numbers of yarn loops between the face yarn layer12and the ground yarn layer11, since provides step B22that further irons the knitted fabric10after the knitted fabric10is formed to increase flatness of the knitted fabric10.

Please refer toFIG.2andFIG.27. Based on the foregoing description, in one embodiment, the at least one face yarn123is composed of the base yarn124and the polyurethane (PU) layer125which is wrapped around the outer surface of the base yarn124and comprises the leather fibers122. Since the at least one face yarn123may shrink after being manufactured, the manufacturing method20further includes step C23: hot pressing the face yarn layer12after ironing the knitted fabric10. A heating copper piece or other objects with same functions can be implemented in step C23to perform hot pressing. Furthermore, step C23practically performs hot pressing on one single side of the face yarn layer12to prevent the at least one face yarn123from shrinking to causes the knitted fabric10curling.

Please refer toFIG.27andFIG.28. In one embodiment, the manufacturing method20includes step D24: disposing a thermoplastic film30on the face yarn layer12, and hot pressing the thermoplastic film30to form a reinforcing layer31. In this embodiment, the knitted fabric10is hot pressed twice, wherein first is performed in step C23, and second is performed in step D24. However, there are two different subjects be hot pressed, one is that the face yarn layer12is hot pressed in the first hot pressing, and the other is that the thermoplastic film30is hot pressed in the second hot pressing. The thermoplastic film30after being hot pressed not only improves a strength of the face yarn layer12, but also improves a gloss of the face yarn layer12, so that the tactile feeling of the face yarn layer12is to be smoother, and the knitted fabric10is more aesthetic visually. In another embodiment, a mold (not shown in the figures) is applied to hot press on the thermoplastic film30in step D24to form a plurality of leather textures on the reinforcing layer31. Thus, not only the visual aesthetics of the knitted fabric10can be enhanced through the foregoing embodiment, but also the strength of the knitted fabric10can be enhanced.