Composite Textile Fabrics with Segmented Floating Regions

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Solution Overview

Problem

Composite textile fabrics used in garments with bi-component plaited knit construction can stick to the skin during high exertion activities, reducing airflow and sweat evaporation, leading to a chilling effect after activity.

Innovation Solution

A composite textile fabric with a first high shrinkage yarn layer and a second low shrinkage or no shrinkage yarn layer, formed in a plaited construction, where the second layer includes anchored and floating regions. The fabric is exposed to heat, causing the first layer to shrink and the floating regions to separate, creating air gaps for ventilation and reducing skin contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bi-component plaited knit construction is used with a first fabric layer worn towards the skin and a second fabric layer optimized to dry quickly, then moisture management is improved, but the first fabric layer tends to stick to the skin during high exertion activity, reducing airflow and sweat evaporation

Engineering Contradiction:

Improvemoisture managementVSAvoidskin sticking

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The second fabric layer is segmented into anchored regions and floating regions, creating a non-uniform structure where only portions of the layer contact the skin. This segmentation reduces overall skin contact area while maintaining moisture management benefits in the anchored regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a planar fabric structure to a three-dimensional structure by creating floating regions that extend outward from the first fabric layer. This dimensional change creates air gaps between the fabric and skin, improving airflow and reducing skin sticking while maintaining moisture wicking in the anchored regions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If the first fabric layer is designed to move moisture away from the skin, then moisture transport is improved, but air flow and sweat evaporation are reduced due to skin contact

Engineering Contradiction:

Improvemoisture transportVSAvoidreduced airflow

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Different regions of the second fabric layer are assigned different functions: anchored regions provide moisture transport and skin contact, while floating regions provide airflow channels and evaporation space. This local differentiation allows simultaneous optimization of moisture transport and airflow.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The floating regions act as an intermediary air space between the skin and the external environment, facilitating sweat evaporation while the anchored regions maintain moisture wicking. This intermediary structure resolves the conflict between moisture transport and airflow.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If the fabric layers are constructed to provide thermal insulation, then thermal protection is improved, but skin contact is increased which may reduce ventilation

Engineering Contradiction:

Improvethermal insulationVSAvoidreduced ventilation

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The segmented structure with anchored and floating regions allows the fabric to provide thermal insulation through the fabric layers while simultaneously creating ventilation channels in the floating regions. This segmentation enables both thermal protection and airflow.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The floating regions create a porous, air-filled structure that provides both thermal insulation (through trapped air) and ventilation (through airflow channels). This porous architecture simultaneously achieves thermal protection and breathability.

Inventive Principle:

Principle #31Porous materials

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

Facilitates ventilation and reduces skin contact, enhancing moisture evaporation and providing thermal insulation by creating air gaps between the skin and the fabric layer, while maintaining comfort and flexibility.

Implementation Method 1

exposing the fabric body to heating sufficient to cause the first fabric layer to shrink relative to the second fabric layer such that the floating regions separate (buckle outwardly) from the first fabric layer

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Data Source

PatentUS11840054B2Composite textile fabrics

Publication Date: 2023.12.12 MMI IPCO LLC

AI summary

A composite textile fabric that includes a first (face) fabric layer, and a second (back) fabric layer that is formed concurrently with the first fabric layer in a plaited construction. The second fabric includes a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer. The second fabric layer also includes a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions.