Composite Yarn Sock Float Loops Durability
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Solution Overview
Problem
Conventional socks with pile yarn and polyurethane yarn loops provide improved cushioning but become loose, increasing friction and reducing durability, making them unsuitable for long-term use, especially for factory workers.
Innovation Solution
A sock design where woolly-processed yarn and cellulose fiber yarn, hemp yarn, silk yarn, or acrylic yarn are alternately knitted into float loops with a ground yarn, enhancing cushioning and strength, and the polyurethane yarn is used for plain knitting to prevent slipping without protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pile yarn and polyurethane bare yarn are knitted into loops to improve cushioning properties, then cushioning properties are improved, but the fabric becomes loose and friction increases causing damage to the pile yarn, reducing durability
Solution Approach 1:
The patent combines woolly-processed yarn (providing stretchability and cushioning) with cellulose fiber yarn, hemp yarn, silk yarn, animal hair, or acrylic yarn (providing strength and durability) to create a composite yarn structure. This composite approach allows the sock to simultaneously achieve improved cushioning properties through the woolly component while maintaining durability through the strength-providing component, resolving the contradiction between comfort and longevity.
Solution Approach 2:
The patent changes the material parameters by specifying that component yarns should be composed of two different types of yarns with complementary properties. The first yarn (woolly-processed) provides elasticity and cushioning, while the second yarn (cellulose fiber, hemp, silk, animal hair, or acrylic) provides strength. This parameter change in yarn composition allows the fabric to maintain tightness while providing cushioning, preventing the looseness and damage that occurs with conventional single-yarn approaches.
2Strength
If stitches are formed by knitting pile yarn and polyurethane bare yarn into loops, then cushioning properties are improved, but the fabric becomes loose increasing friction between pile yarn and contact area, causing damage
Solution Approach 1:
The use of composite yarns combining woolly-processed yarn with strength-providing yarns (cellulose fiber, hemp, silk, animal hair, or acrylic) creates a more robust stitch structure. The strength-providing component prevents the fabric from becoming loose during knitting and wear, thereby reducing excessive friction between the pile yarn and the contact area, and preventing damage to the cushioning structure.
Solution Approach 2:
The patent applies different yarn properties to different functional requirements within the same yarn structure. The woolly-processed portion of the composite yarn provides local cushioning quality, while the cellulose fiber/hemp/silk/animal hair/acrylic portion provides local strength quality. This local differentiation allows the fabric to maintain proper tension and reduce friction damage while preserving cushioning properties.
3Strength
If conventional pile yarn and polyurethane bare yarn are used for cushioning, then cushioning properties are improved, but the sock cannot be used for a long period of time
Solution Approach 1:
The patent employs composite yarns where woolly-processed yarn provides cushioning properties and cellulose fiber yarn, hemp yarn, silk yarn, animal hair, or acrylic yarn provides enhanced strength and durability. This composite structure enables the sock to maintain its cushioning function over an extended service life, as the strength-providing component prevents fabric degradation and wear that would otherwise limit the sock's usable duration.
Solution Approach 2:
The patent changes the durability parameter by introducing yarns with inherently higher strength and wear resistance (cellulose fiber, hemp, silk, animal hair, or acrylic) into the composite structure. This parameter change in material composition allows the sock to withstand prolonged use and repeated washing, extending the service life from conventional short-term use to long-term durability suitable for factory workers and other demanding applications.
Data Source
AI summary
A conventional sock, in which a pile yarn knitted into loops together with a polyurethane yarn has cushioning properties, but has a problem in that it cannot be used for a long period of time. According to the present invention, a first component yarn 15a composed of two yarns, namely, a woolly nylon yarn 13a and a cotton yarn 14a, and a second component yarn 15b composed of two yarns, namely, a woolly nylon yarn 13b and a cotton yarn 14b, are alternately knitted into float loops every 10 loops. Accordingly, the cotton yarns that are less stretchable appear on the surface, and thus cushioning properties can be improved. Also, the yarn strength can be increased by the woolly nylon yarns that are highly stretchable, and also the strength can be further increased by using the component yarns each composed of two yarns: a woolly nylon yarn; and a cotton yarn. Accordingly, the obtained sock can be used for a long period of time.