Double Layer Knitted Element With Tucked Functional Yarns

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Solution Overview

Problem

Existing knitting methods face challenges in controlling the distribution and visibility of stiffening or elastic yarns within knitted fabrics, leading to inconsistent properties and risk of yarn pulling, which affects the fabric's appearance and functionality.

Innovation Solution

A double layer knitted element with a third yarn sandwiched between two layers, attached by tuck stitches with a miss stitch between successive tuck stitches, allowing for independent enhancement of properties like stiffness and elasticity without altering the knitting sequence or surface appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If in-laid elastic yarns are used to achieve stretch and recovery properties, then the fabric gains elastic functionality, but the elastic yarn is at risk of pulling out because it is not connected to the fabric

Engineering Contradiction:

Improveelastic yarn retentionVSAvoidfabric integrity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The elastic yarn is pre-connected to the knit fabric through tuck stitches during the knitting process itself, before the fabric is removed from the machine. This preliminary connection ensures the elastic yarn remains securely integrated throughout subsequent handling and washing, eliminating the pulling out risk while maintaining fabric integrity.

Inventive Principle:

Principle #10Preliminary action

2Strength

If melting yarn is plated or mixed with base yarn to achieve stiffness, then the fabric gains stiffness, but the amount of melting yarn is difficult to control and depends on the knitting structure

Engineering Contradiction:

Improvefabric stiffnessVSAvoidmelting yarn distribution control

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The melting yarn is distributed through specific tuck stitches at predetermined locations within the knit fabric, creating localized stiffening zones. This approach allows precise control over where stiffness is applied (e.g., toe cap, heel counter areas) and how much melting yarn is present in each zone, independent of the overall knitting structure.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the knitting sequence is modified to place melting yarn on one side of the fabric, then the melting yarn can be activated at targeted locations, but the visual appearance and properties of the fabric are altered

Engineering Contradiction:

Improvetargeted melting yarn activationVSAvoidfabric appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The double layer knit fabric acts as an intermediary structure that allows melting yarn to be positioned and activated at targeted locations without affecting the external appearance. The melting yarn can be tucked into the inner layer where it remains invisible from the outside, yet still provides stiffness and structural support where needed.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If plating is used to control melting yarn distribution, then yarn distribution is improved, but it is difficult or time consuming to set up and adjust on the knitting machine

Engineering Contradiction:

Improvemelting yarn distribution controlVSAvoidknitting machine setup and adjustment

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The knitting machine uses its existing tuck stitch mechanism to automatically distribute and secure the melting yarn during the normal knitting process. This self-service approach eliminates the need for separate plating setup and adjustment procedures, as the tuck stitch mechanism already exists on standard knitting machines and can be programmed through conventional knitwear design software.

Inventive Principle:

Principle #25Self-service

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

This method ensures the third yarn is securely locked within the fabric, providing enhanced functional properties like stretch, recovery, or compression without affecting the fabric's appearance, and allows targeted activation of melting yarns for added functionality.

Implementation Method 1

the third yarn is attached to one of the first and second layer by a plurality of tuck stitches

Methodology Applied

Scientific EffectTuck stitch mechanical attachment: Mechanical Fastener

Implementation Method 2

activate the melting yarn at targeted locations of the knit fabric

Methodology Applied

Scientific EffectThermal melting: Melting

Implementation Method 3

it is possible to activate the melting yarn only on the inner side of one of the two layers

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentEP4001484B1Double layer knitted element comprising functional tucked-in yarns, shoe upper and shoe comprising the same

Publication Date: 2024.05.08 ADIDAS AG

Figure 1A~1C
Figure 2~3B
Figure 4~5

AI summary

The present invention relates to a double layer knitted element, in particular for a sports article, comprising a first layer (100) comprising a first yarn (110), and a second layer (200) comprising a second yarn (210), and a third yarn (310) arranged at least in part between the first and second layer (100, 200), wherein the third yarn (310) is attached to at least one of the first and second layer (100, 200) by a plurality of tuck stitches, wherein there is at least one miss stitch between two successive tuck stitches of the third yarn (310).