Orthopaedic Brace Knit Structure With Localized Padding Zones
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Solution Overview
Problem
Existing orthopaedic braces face issues with mechanical property alterations due to welding or sewing techniques used for applying functional elements, leading to reduced durability and increased weight, while current knitted articles lack adequate cushioning and breathability.
Innovation Solution
A knitted article with integrated padded zones and flat-knitted zones, using a padding yarn interposed between layers to create localized padding, and tunnels for functional elements, produced through a numerically controlled knitting process without altering mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or sewing techniques are used to apply functional elements to the textile base, then functional elements can be securely attached, but the mechanical properties of the brace are altered and durability is reduced
Solution Approach 1:
The functional elements are integrated into the knitting structure itself rather than being attached separately. The containment pockets and paddings are formed as integral parts of the knitted fabric, eliminating the need for welding or sewing operations that would compromise the textile base's mechanical properties.
Solution Approach 2:
The brace is divided into distinct functional zones (compression zones, cushioning zones, reinforcement zones) that are knitted with different properties in different areas. This allows each zone to be optimized for its specific function while maintaining the overall integrity of the textile base without requiring additional attachment operations.
2Object-affected harmful factors
If padding layers are added throughout the entire extension of the brace, then cushioning is provided, but the brace becomes more rigid and heavier
Solution Approach 1:
Padding is applied locally only in specific zones where cushioning is required (such as areas requiring soft tissue protection), rather than uniformly throughout the entire brace. This allows the brace to provide necessary cushioning while maintaining lower weight and flexibility in non-padding zones.
3Strength
If dense mesh knitting is used throughout the entire brace, then compression and support are provided, but breathability is reduced
Solution Approach 1:
The knitting density is varied locally across different zones of the brace. Areas requiring high compression use denser mesh patterns, while areas requiring breathability use more open, less dense patterns. This spatial variation allows the brace to provide necessary compression support while maintaining adequate breathability in appropriate zones.
Data Source
AI summary
A knitted article 1, in particular for an orthopaedic brace, with a plurality of zones having different cushioning properties, including at least one flat-knitted zone 10 and at least one padded zone 20, comprises a lower layer 30 consisting of several rows of knitted stitches obtained by knitting a corresponding flat-knitted thread, an upper layer 40 consisting of several rows of knitted stitches obtained by knitting a corresponding flat-knitted thread, and a padding layer 50 obtained by a padding yarn different from the flat-knitted thread in that it comprises at least one bundle of padding threads. In particular, the flat-knitted zone 10 consists of the lower and upper layers 30, 40 connected to each other. The padded zone 20, on the other hand, consists of the padding layer 50 interposed between the lower and upper layers 30, 40, for that the padding yarn is laid in at least one row of knitted stitches of the lower and/or upper layer. The present invention also refers to a process for making a knitted article.