3D knitted structure and a method of providing a 3D knitted structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D knitting technologies in automotive applications face challenges in reducing waste and labor costs, as they require post-production cutting, trimming, and finishing, and lack efficient methods for integrating structural elements and cabling management.
Innovation Solution
A method involving the combination of heat-activated and non-heat-activated yarns in 3D knitting to form integrally formed channels, which are then heat-treated to create a stiffened structure, allowing for reduced post-production processing and integrated cabling management without additional accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If 3D knitting technology is used to manufacture automotive covers, then material waste is reduced and labor costs are lowered, but the structural stiffness and shape retention are insufficient
Solution Approach 1:
The patent combines heat-activated yarns (thermoplastic material) with non-heat-activated yarns to create a composite knitted structure. The heat-activated yarns melt during heat treatment to form binding nodes that stiffen the structure, while the non-heat-activated yarns maintain the flexible knitted appearance. This composite approach resolves the contradiction by integrating both waste reduction (through 3D knitting) and structural stiffness (through heat-treated composite material).
Solution Approach 2:
The patent applies heat treatment to change the physical state of the heat-activated yarns from solid to melted, then solidified, transforming the flexible knitted structure into a stiffened structure with improved shape retention. This parameter change (temperature-induced phase transition) resolves the contradiction between maintaining flexibility and achieving structural stiffness.
2Strength
If traditional knitting methods are used, then structural stiffness can be achieved, but material waste increases and labor costs rise due to post-production cutting and trimming
Solution Approach 1:
The patent performs the stiffening action during the knitting process itself by incorporating heat-activated yarns that will be activated later through heat treatment. This preliminary integration of the stiffening mechanism eliminates the need for post-production cutting and trimming, as the cover is knitted in its final shape with embedded structural reinforcement. The heat treatment activates the pre-integrated heat-activated yarns to provide stiffness without requiring additional material removal or assembly steps.
Solution Approach 2:
The patent merges the structural reinforcement function directly into the knitting process by integrating heat-activated yarns within the knitted structure. Instead of adding separate stiffening components after manufacturing, the structural reinforcement is combined with the cover material itself through the heat treatment process, eliminating material waste associated with separate assembly operations.
3Ease of operation
If additional accessories are added for cabling management, then cable organization is improved, but device complexity and labor costs increase
Solution Approach 1:
The patent creates multi-functional knitted channels within the cover structure that simultaneously serve as structural elements and cable management conduits. These channels are integrated into the knitted fabric itself, allowing cables to be routed and organized without requiring separate clips, fixings, or conduit accessories. The knitted channels perform multiple functions: providing structural support, enabling cable routing, and maintaining cover integrity, thereby reducing device complexity while improving ease of operation.
Solution Approach 2:
The knitted channels are designed to self-containedly manage cables without requiring additional accessories. The channels are formed as integral parts of the knitted structure, providing built-in cable routing capabilities that eliminate the need for separate cable management components. The structure serves itself by incorporating the cable management function directly into the cover material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes waste and labor costs by producing vehicle components with increased stiffness and integrated cabling management, reducing the need for additional accessories and ensuring the cover retains its shape over time.
Implementation Method 1
a yarn formed from a material that melts when heated to an activation temperature of the yarn. The heat activated yarn comprise a thermoplastic material.
Implementation Method 2
applying a heat treatment process to the 3D knitted structure to form the cover... during the heat treatment process in which the cover is heated to a temperature at or above an activation temperature
Data Source
AI summary
Aspects of the present invention relate to a method (500) of fabricating a cover for an interior trim component or an exterior trim component for a vehicle. The method comprising forming a 3D knitted structure (510) by knitting together at least one heat activated yarn and at least one non-heat activated yarn. The structure may be arranged whereby, during a subsequent heat treatment process (520) in which the cover is heated to a temperature at or above an activation temperature, the heat-activated yarn is activated thereby to form an automotive cover having a knitted structure of increased stiffness once cooled.