Activatable Yarn Aperture Formation in Knit Components
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Solution Overview
Problem
Existing knit components require post-processing alterations or modifications to the knitting process to create apertures, which is time-consuming and inefficient.
Innovation Solution
Incorporating an activatable yarn type that responds to stimuli such as thermal energy or aqueous solutions to form apertures between stable yarn courses, eliminating the need for post-processing alterations and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If post-processing alterations or modifications to the knitting process are used to create apertures, then apertures can be formed in knit components, but the process becomes time-consuming and inefficient
Solution Approach 1:
The patent applies preliminary action by incorporating activatable yarn into the knitting process before the aperture formation is needed. The yarn is knitted in place during normal manufacturing, and then activated later to dissolve and form the aperture. This eliminates the need for separate post-processing steps to create apertures, as the structure is prepared in advance and automatically forms when activated.
Solution Approach 2:
The patent replaces mechanical aperture creation methods (such as cutting, punching, or complex knitting pattern modifications) with a chemical/thermal activation process. The activatable yarn responds to stimuli like heat or chemicals to dissolve and form apertures automatically, substituting manual or mechanical post-processing operations with an automated activation mechanism that reduces manufacturing time.
2Productivity
If activatable yarn is used to form apertures, then manufacturing time is reduced and efficiency is improved, but the complexity of the knitting process increases
Solution Approach 1:
The patent applies parameter changes by using yarn with specific physical or chemical properties that allow it to respond to stimuli. The activatable yarn is formulated with different melting points, solubility characteristics, or thermal responses compared to conventional yarn. This allows the yarn to remain stable during knitting but dissolve or melt when exposed to specific conditions, enabling aperture formation without complex mechanical processes.
Solution Approach 2:
The patent employs composite materials by combining activatable yarn with stable yarn in the same knit component. The composite structure allows different regions to have different properties: the activatable yarn forms apertures where needed while the stable yarn maintains the overall structure. This material combination enables automated aperture formation while keeping the overall knitting process relatively simple.
3Ease of manufacture
If activatable yarn is incorporated into stable yarn courses, then apertures can be formed between courses, but the structural integrity of the knit component may be compromised
Solution Approach 1:
The patent applies local quality by placing activatable yarn specifically at locations where apertures are needed, rather than throughout the entire knit component. The activatable yarn is incorporated into specific courses or regions, while stable yarn maintains the overall structural framework. This localized approach allows aperture formation in specific areas without compromising the overall structural integrity of the knit component.
Solution Approach 2:
The patent uses composite materials by combining activatable yarn with stable yarn in a coordinated manner. The stable yarn provides the structural framework that maintains integrity, while the activatable yarn is strategically positioned to form apertures. The composite structure ensures that the removal or dissolution of the activatable yarn does not compromise the overall strength and stability of the knit component.
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
Enables quick and efficient formation of apertures in knit components by dissolving or melting the activatable yarn, maintaining the structural integrity of stable yarn courses and reducing manufacturing time and complexity.
Implementation Method 1
the activatable yarn responds to a stimulus (such as thermal energy or an aqueous solution) such that the activatable yarn dissipates, dissolves, or melts thereby forming an aperture in the knit component
Implementation Method 2
the activatable yarn responds to a stimulus (such as thermal energy or an aqueous solution) such that the activatable yarn dissipates, dissolves, or melts thereby forming an aperture in the knit component
Data Source
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AI summary
Aspects herein include a knit component having one or more first knit courses and one or more second knit courses. One or more apertures are positioned between the one or more first knit courses and the one or more second knit courses. The one or more apertures may be formed by an activatable yarn type being exposed to a stimulus.