Double Selection Fabric Blister Zones With Multi-Yarn Inlay Control
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Solution Overview
Problem
Existing methods for manufacturing double selection fabrics with blister zones face limitations in creating flat/deep areas due to the presence of inlay yarns, which can cause defects like 'popping out inlay' and restrict the use of multiple colors, leading to restricted design possibilities.
Innovation Solution
The method involves using different inlay yarns in various blister zones, where one yarn is inserted between the layers and the other is knitted to the back layer, allowing for multiple blister zones with distinct properties and colors, and eliminating inlay yarns from flat areas to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If inlay yarn is permanently laid between back and front layers to create voluminous appearance, then blister zones with volume are achieved, but flat areas cannot be created and inlay yarn pops out creating defects
Solution Approach 1:
The fabric is divided into distinct zones: blister zones where inlay yarn creates volume, and flat areas where inlay yarn is excluded or knitted to the back layer. This segmentation allows different regions to have different properties without interference
Solution Approach 2:
The inlay yarn treatment is made dynamic by selectively knitting it to the back layer in certain zones while leaving it loose in other zones. This dynamic control prevents popping out in flat areas while maintaining volume in blister zones
2Shape
If inlay yarn is used to create voluminous blister zones, then volume is achieved, but only one color of inlay yarn can be used
Solution Approach 1:
Multiple inlay yarns of different colors are introduced and assigned to different blister zones. Each zone can be configured to use a specific colored inlay yarn, enabling multi-color voluminous effects throughout the fabric
Solution Approach 2:
Different colored inlay yarns are used in different zones of the fabric. Each blister zone has its own specific color property, allowing for localized color variation while maintaining volume in each zone
3Shape
If inlay yarn is laid between layers to create blister zones, then volume is achieved, but large flat areas cannot be created without inlay popping out
Solution Approach 1:
The inlay yarn is extracted or removed from flat areas where it would cause popping defects. By excluding the inlay yarn from these regions or knitting it securely to the back layer, large flat areas can be created without the harmful popping effect
Solution Approach 2:
The inlay yarn configuration is dynamically adjusted: loose between layers in blister zones for volume, and knitted to the back layer in flat areas to prevent popping. This dynamic switching enables both voluminous and flat regions
Data Source
AI summary
A method of manufacturing a double selection fabric including a back layer, a front layer, and least a first and a second blister zone having different physical properties is provided, the method including: inserting in the first blister zone a first inlay yarn between the back layer and the front layer of the double selection fabric, and knitting a second inlay yarn to the back layer, wherein the second inlay yarn is different from the first inlay yarn; inserting in the second blister zone the second inlay yarn between the back layer and the front layer of the double selection fabric, and knitting the first inlay yarn to the back layer; and knitting the first and second inlay yarns to the back layer of the double selection fabric outside of the at least first and second blister zones. Double selection fabrics prepared by the methods are also provided.