Double-sided plush knitted fabric
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Solution Overview
Problem
Existing double-sided cut-loop piles fabrics have weak connections between front and back piles, leading to pile detachment and reduced softness due to the need for low-melting-point fibers and post-processing hot-melt methods.
Innovation Solution
A double-sided plush fabric is created using a circular knitting machine, where cut-loop piles are directly produced during knitting, allowing for adjustable lengths and stronger structural connections between piles and the basic structure, eliminating the need for post-processing loop-cutting and using low-melting-point fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If loop-cutting processing is performed on knitted fabric to form piles, then piles are formed, but the length of piles becomes significantly shorter than the original yarn loops and plush cannot be formed
Solution Approach 1:
The patent applies preliminary action by forming the piles during the knitting process itself rather than performing loop-cutting after knitting. The circular knitting machine directly produces cut-loop piles with controlled lengths (3.5mm to 15mm) as part of the knitting operation, preventing the piles from being significantly shortened by post-knitting cutting operations.
2Strength
If low-melting-point fibers are used to strengthen connection between cut-loop piles and basic structure, then connection strength is improved, but fabric softness is reduced
Solution Approach 1:
The patent extracts the low-melting-point fibers and hot-melt post-processing step from the manufacturing process. Instead of using these fibers to strengthen connections, the invention relies on the structural design where arcuate yarn segments naturally connect cut-loop piles to the basic structure, eliminating the need for chemical or thermal bonding agents that compromise softness.
Solution Approach 2:
The patent changes the structural parameters of the fabric by using arcuate yarn segments with specific geometries that provide mechanical interlocking and natural connection strength. This structural approach replaces the need for low-melting-point fibers, maintaining fabric softness while achieving sufficient connection strength between piles and the basic structure.
3Ease of manufacture
If post-processing loop-cutting operation is performed, then piles are formed, but the process becomes more complex and pile length control is limited
Solution Approach 1:
The patent merges the pile formation operation with the knitting process itself. The circular knitting machine performs both knitting and cut-loop pile formation in a single integrated operation, eliminating the need for separate post-processing loop-cutting steps. This combination simplifies the manufacturing process while providing full adaptability in pile length control through machine settings.
4Device complexity
If connection relationship between front and back cut-loop piles and basic structure is weakened, then fabric structure is simplified, but piles become prone to fall off
Solution Approach 1:
The patent uses arcuate (curved) yarn segments to connect cut-loop piles to the basic structure. The curved geometry of these yarn segments creates a natural mechanical interlock and distributes stress more effectively, strengthening the connection between piles and the basic structure without adding complex multi-layer constructions or additional fastening mechanisms.
Data Source
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AI summary
A double-sided plush fabric (20) formed by knitting with a circular knitting machine, the double-sided plush fabric (20) includes a basic structure (21) and two plush structures (22, 23) respectively connected to the basic structure (21) and positioned on two opposite sides of the basic structure (21), each of the two plush structures (22, 23) includes a plurality of cut-loop piles (221, 231), and a length of the cut-loop piles (221, 231) of the two plush structures (22, 23) is in a range from 3.5 mm to 15 mm, each of the two plush structures (22, 23) includes a plurality of arcuate yarn segments (223, 233) connected with the basic structure (21), one of the two plush structures (22) is connected to two of the cut-loop piles (221) by the continuous arcuate yarn segments (223), and the other one of the two plush structures (23) is connected to two of the cut-loop piles (231) by one of the arcuate yarn segments (231).