Compression Hosiery Knitting for Smooth Interior Patterned Fabric
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Solution Overview
Problem
Existing compression hosiery products often have a rough interior surface with loose threads and ridges, which can cause discomfort and indentations, and lack decorative patterns similar to non-compression hosiery.
Innovation Solution
A 4-feed circular knitting machine is used to create a compression hosiery product with a smooth interior surface and decorative patterns by plating elastomer and non-elastomer yarns, where elastomer compression yarns are inlaid to the inner surface and pattern yarns are plated to the outer surface, using a method that involves introducing yarns into specific needle selections to define a pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If compression hosiery is made with traditional patterning techniques, then decorative patterns are achieved, but the interior surface becomes rough with loose threads and ridges causing discomfort
Solution Approach 1:
The patent divides the knitting process into separate functional zones using multiple needle selections. Pattern yarns are introduced only to specific needles that form the decorative design, while other needles receive only smooth compression yarns. This segmentation allows the exterior to display patterns while the interior remains smooth, eliminating loose threads and ridges that cause discomfort.
Solution Approach 2:
The invention applies different yarn types and knitting densities to different regions of the hosiery. The exterior surface receives pattern yarns in specific areas to create decorative effects, while the interior surface consistently receives only smooth compression yarns. This local differentiation ensures decorative patterns are visible where needed while maintaining comfort-critical smooth interiors.
2Ease of manufacture
If compression hosiery uses single-feed knitting machines, then production is simpler, but decorative pattern capability is limited
Solution Approach 1:
The patent configures a multi-feed knitting machine to perform multiple functions simultaneously: Feed 1 provides compression yarns for structural integrity, Feeds 2 and 4 provide pattern yarns for decorative designs, and Feed 3 provides additional compression yarns. This multi-functional setup enables both decorative patterning and compression therapy in a single manufacturing process, eliminating the need for separate operations.
Solution Approach 2:
The invention combines different yarn types from multiple feeds into a single composite knitted structure. Elastomer compression yarns are integrated with decorative pattern yarns through coordinated needle selections, creating a unified fabric that simultaneously provides medical compression functionality and aesthetic decorative patterns.
3Reliability
If compression yarns are knitted throughout the entire hosiery, then medical compression efficacy is maintained, but the appearance resembles traditional medical hosiery rather than fashion hosiery
Solution Approach 1:
The patent applies compression yarns uniformly throughout the hosiery structure to maintain medical efficacy, while strategically applying pattern yarns only to the exterior surface in decorative configurations. This allows the interior to maintain consistent compression properties for health benefits while the exterior displays fashionable patterns that resemble non-medical hosiery.
Solution Approach 2:
The invention separates the compression function from the decorative function by operating in different dimensional layers. Compression yarns form the structural base layer providing medical efficacy, while pattern yarns are overlaid on the exterior surface creating a decorative dimension. This layered approach allows both medical and fashion requirements to be satisfied simultaneously.
Data Source
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AI summary
A compression garment, for example, a sock, formed of a knitted fabric that includes an elastomer compression inlay yarn introduced into a predetermined first selection of needles on a first knitting machine finger position and first and second pattern yarns introduced into a predetermined second selection of needles on second and third knitting machine finger positions, the first selection of needles and the second selection of needles collectively defining a predetermined pattern. When the predetermined second selection of needles is raised to take on the first and second pattern yarns, the elastomer compression inlay yarn deflects predetermined ones of the second selection of needles radially inwardly to define an annular space into which the pattern yarns are dropped in an offset relation to the elastomer compression inlay yarn. The first and second pattern yarns are plated to respective outer and inner surfaces of the fabric, and the elastomer compression yarn are inlaid to the inner surface of the fabric.