Fulldensity patterned plush

The durability of plush fabrics is strongly influenced by the density of the pile. In plain, single-colour pile there is an optimum pile density of one pile loop to each ground loop.

When knitting patterned plush (either in colour or self-colour with different plush heights), optimum pile density cannot be achieved. The reason is that, although the plush yarn plates with a complete ground course on the technical face side, it only produces a part course in pile on the effect side.

Mayer and Cie have developed the model MCPE to knit high-density jacquard plush fabrics, using electronic selection. Two independently-controlled sinkers operate in each trick to separately form the ground yarn and the pile yarns into loops. All the loops are then knocked-over together. On the technical face side, the ground yarn is required to perfectly plate over the pile yarn. One of the sinkers holds down the fabric and the pre-formed ground yarn loop; the other knocks-over and holds-down the pile loops.

At preliminary loop forming, all needles are taken down to 'tucking-on-the-latch' height so the old loops remain on the closed latches. For two-colour plush, at pile feeder for colour A, selected needles rise to receive pile yarn A. At pile feeder for colour B, the remaining needles are selected to receive pile yarn B. At knock over, all the ground and pile loops are knocked over together.

When a needle is not selected to knit the pile yarn, it floats on the pile surface and is clipped out in finishing. It is only knitted into the ground when selected, so there is less wasted yarn.

The 30-inch diameter machine has 48 cam segments. In three-colour plush there will be 12 knock-over/ground segments and 36 pile loop segments, in a sequence of 1:3.

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