Double Selection Fabric Blister Zone Inlay Yarn Insertion
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Solution Overview
Problem
Existing methods for manufacturing double selection fabrics face limitations in creating large flat/deep areas without defects, as inlay yarns can 'pop out' and only allow for a single color, restricting the creation of multiple blister zones with different appearances.
Innovation Solution
The method involves using different inlay yarns for each blister zone, where one yarn is inserted between the layers and the other is knitted to the back layer, allowing for varying properties and colors across zones, and removing inlay yarns from flat areas to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single inlay yarn is used throughout the fabric, then the manufacturing process is simple, but multiple blister zones with different appearances cannot be created
Solution Approach 1:
The fabric is divided into multiple blister zones (first blister zone, second blister zone, etc.), each with different properties. Different inlay yarns are inserted into different zones, allowing each zone to have unique characteristics while maintaining a unified manufacturing process
Solution Approach 2:
Different inlay yarns with different properties are used in different blister zones. Each zone can be customized with specific yarn types, colors, or textures to achieve the desired local appearance and functionality
2Shape
If inlay yarn is inserted between back and front layers throughout the fabric, then continuous volume is achieved, but fabric defects occur in large flat areas
Solution Approach 1:
The fabric is segmented into blister zones where inlay yarn is inserted and flat zones where it is not. This segmentation allows volume to be concentrated in specific areas while maintaining fabric integrity in flat areas, preventing the 'popping out' defect
Solution Approach 2:
Inlay yarn insertion is applied locally only in blister zones rather than uniformly across the entire fabric. This localized approach provides volume where needed while avoiding defects in flat areas
3Adaptability or versatility
If inlay yarn is permanently laid between back and front layers, then volume is provided in blister zones, but only one color of inlay yarn can be used
Solution Approach 1:
The fabric production is segmented into different blister zones, each capable of receiving different inlay yarns. This segmentation enables multi-color or multi-pattern designs by assigning different yarns to different zones
Solution Approach 2:
The inlay insertion mechanism is designed to handle multiple types of inlay yarns (different colors, materials, or properties) and insert them into different zones according to the desired pattern, making the system universally applicable to various design requirements
Data Source
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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.