3D Knit Seamless Backpack Resolving Cut-and-Sew Waste
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Solution Overview
Problem
Traditional backpack manufacturing is labor-intensive, wasteful, and expensive due to the cut and sew process, which requires multiple material elements, stitching, and adhesive bonding, leading to increased waste and difficulty in recycling.
Innovation Solution
Three-dimensional knitting technology allows for the creation of seamless backpacks using computer-aided design to program individual stitches and yarn combinations, reducing the need for cutting and joining, minimizing waste, and enabling the integration of various properties like stretch-resistance and breathability into a single textile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional cut and sew process is used with multiple material elements, then different properties (stretch-resistance, wear-resistance, flexibility) can be imparted to different areas, but labor intensity and production time increase significantly
Solution Approach 1:
The patent combines multiple separate material elements and joining operations into a single integrated 3D knitting process. The knitted bag body is constructed as one seamless piece where different yarn types (elastane for stretch, nylon for strength) are woven together in specific patterns to provide varying properties across different areas without requiring cutting, layering, or stitching of separate materials.
Solution Approach 2:
The 3D knitting machine and yarn selection system serve multiple functions simultaneously: they create the structural form of the bag, provide different mechanical properties in different areas through yarn selection and stitch patterns, and eliminate the need for separate joining processes. This multi-functionality resolves the contradiction by achieving material property distribution without increasing production time.
2Strength
If multiple material elements are joined through stitching and adhesive bonding, then structural strength and durability are improved, but waste material accumulates and disposal becomes difficult
Solution Approach 1:
The patent merges the structural strength function and waste reduction by creating a seamless knitted structure where strength comes from the interlocking yarns and stitch patterns themselves rather than from separate joining operations. This eliminates cut-off waste and reduces adhesive waste while maintaining structural integrity through the inherent strength of the knitted construction.
Solution Approach 2:
The patent changes the fundamental parameter of construction from piecewise assembly to continuous knitting. By varying stitch types, yarn tension, and yarn composition during the knitting process, the structure achieves different strength characteristics in different areas without requiring additional materials or joining operations, thus preventing waste generation.
3Adaptability or versatility
If numerous different material elements are incorporated into the backpack, then desired properties are achieved, but the complexity of stocking, cutting, and joining increases
Solution Approach 1:
The patent combines the functions of multiple material elements into a single knitted fabric by using different yarn types (elastane, nylon, polyethylene) in the same knitting process. The yarn selection system and stitch patterns provide stretch-resistance, wear-resistance, and flexibility in different areas without requiring separate materials to be stocked, cut, and joined, thereby reducing assembly complexity while maintaining desired properties.
4Manufacturing precision
If manual cutting and bonding processes are used, then precise shaping and joining are achieved, but human error increases production variation
Solution Approach 1:
The patent replaces manual mechanical cutting and bonding operations with an automated 3D knitting system that uses programmed needle movements and yarn feeding mechanisms. This automated system consistently reproduces the same stitch patterns and yarn combinations, eliminating human error in shaping and joining while maintaining the precision needed for complex bag designs.
Data Source
AI summary
A bag assembly has a primary storage chamber and a carrying structure, and the carrying structure having a panel and a shoulder strap extending from the panel. The strap and the panel are seamlessly integrated. The primary storage chamber is a first three dimensional (3D) knit structure having a first material or combination of materials and the carrying structure is a second 3D knit structure having a second material or combination of materials. The primary storage chamber is fixed to the panel of the carrying structure to form the bag assembly. Also provided is a bag assembly in which the primary storage chamber is a first 3D knit structure having a first knit pattern and the carrying structure is a second 3D knit structure having a second knit pattern. Also provided is a method for customizing locations of 3D knit features based on user dimensions.