Double-Knit Fabric Anchored Lines Detached Regions Insulation
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Solution Overview
Problem
Performance fabrics like fleece often suffer from fiber breakage during brushing, leading to microfiber pollution and reduced insulation performance over time.
Innovation Solution
A double-knit fabric structure featuring a first knit layer, a second knit layer, and stuffer yarns between them, with anchored lines and detached regions that provide insulation and minimize fiber loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fleece fabric is mechanically brushed to raise the fiber surface for improved insulation, then insulation performance is improved, but fiber breakage occurs leading to microfiber pollution and deterioration of insulation performance over time
Solution Approach 1:
The fabric is constructed as a double-knit structure with two separate knit layers (first knit layer and second knit layer) that are selectively anchored together at anchored lines while remaining detached in detached regions. This segmentation prevents the mechanical brushing process from causing widespread fiber breakage while maintaining insulation performance through the layered structure.
Solution Approach 2:
The fabric exhibits different structural properties in different regions: anchored lines provide structural stability and prevent fiber loss where layers are knitted together, while detached regions maintain high insulation performance with minimal fiber interference. This local differentiation allows the fabric to resist fiber pollution in critical areas while preserving insulation benefits in other areas.
2Temperature
If fleece fabric is mechanically brushed to raise the fiber surface, then insulation performance is improved, but fiber loss occurs during washing and over time
Solution Approach 1:
The double-knit structure with separated layers reduces fiber loss by preventing the mechanical action that causes fiber detachment. The anchored lines securely bind layers together, preventing fiber loss during washing, while the overall structure maintains insulation performance without requiring extensive mechanical brushing.
Solution Approach 2:
The fabric structure is pre-configured with anchored lines and detached regions before any washing or wear occurs. This preliminary structural arrangement prevents fiber loss from occurring in the first place, rather than attempting to repair or restore the fabric after fiber loss has occurred during washing.
3Weight of moving object
If a low weight fabric is designed, then productivity and ease of use are improved, but insulation performance may be compromised
Solution Approach 1:
The double-knit fabric with two separate layers and air gaps in detached regions provides high insulation performance relative to its weight. The segmented structure traps air more effectively than a solid fabric of equivalent weight, delivering superior thermal insulation without sacrificing weight efficiency.
Solution Approach 2:
The fabric incorporates air pockets and gaps within the detached regions between knit layers, creating a porous structure that enhances insulation performance. This porous architecture provides high thermal resistance per unit weight, allowing the fabric to maintain light weight while achieving excellent insulation properties.
Data Source
AI summary
A double-knit fabric containing a first knit layer, a second knit layer, and a plurality of stuffer yarns. The first knit layer contains a plurality of first yarns and forms the upper surface of the double-knit fabric. The second knit layer contains a plurality of second yarns and forms the lower surface of the double-knit fabric. The plurality of stuffer yarns is located between the first knit layer and the second knit layer. The double-knit fabric contains a plurality of anchored lines and a plurality of detached regions. The double-knit fabric the first knit layer has an undulating surface in at least 90% by number of the detached regions defined as the upper surface containing at least 3 inflection points in the warp or weft directions.