Elastic Knitted Fabric Insert Using Partial Weft Yarns
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Solution Overview
Problem
Existing elastic fixing inserts for clothing, particularly those using knitted fabrics, face challenges in achieving sufficient elasticity and softness while being cost-effective and easy to produce, as they often rely on complex yarn structures or specialized machinery.
Innovation Solution
A knitted fabric insert is developed using at least two warp thread systems, where one system is inserted as a partial weft, utilizing non-elastic staple fiber yarns for high elasticity and textured filaments for enhanced stretchability, allowing for production on conventional machines and achieving high elasticity values without the need for specialized yarns or machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If textured yarns or false-twist textured polyester filament yarns are used to achieve elasticity, then the insert becomes highly elastic, but the production complexity increases and specialized machinery is required
Solution Approach 1:
The patent changes the fundamental parameter of yarn selection from elastic textured yarns to non-elastic staple fiber yarns, achieving elasticity through a different mechanism (loop structure formation during knitting) rather than through the inherent properties of the yarn itself. This allows production on conventional knitting machines without specialized equipment.
Solution Approach 2:
The patent replaces the mechanical texturing process (which requires specialized machinery) with a knitting process that inherently creates elastic loop structures. The elasticity is generated by the knitted fabric's ability to deform and recover, rather than by pre-textured yarns, thus eliminating the need for complex texturing equipment.
2Ease of operation
If roughening processes are applied to achieve softness and textile feel, then the insert becomes softer, but additional production steps are required
Solution Approach 1:
The patent uses the inherent properties of staple fiber yarns (natural softness and textile feel) to achieve the desired softness without requiring additional roughening or texturing processes. The yarns themselves provide the soft hand feel, eliminating the need for separate finishing steps.
Solution Approach 2:
The patent achieves uniform softness throughout the fabric by using consistent staple fiber yarns in the knitting process, rather than requiring post-production roughening treatments that may create uneven surfaces. The softness is built into the fabric structure from the beginning.
3Stability of the object's composition
If multiple warp thread systems are used to achieve high elasticity, then the elasticity increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent divides the knitting process into distinct zones with different needle types (elasticity-producing needles in specific rows, standard needles in other rows) to create varying degrees of elasticity in different areas of the fabric. This segmented approach allows control over elasticity distribution while using conventional machine capabilities.
Solution Approach 2:
The patent applies elasticity-enhancing knitting techniques only in specific rows or zones where high elasticity is needed, rather than throughout the entire fabric. This partial application maintains high elasticity where required while simplifying the overall manufacturing process for areas where standard knitting suffices.
Data Source
AI summary
This invention describes an elastic (fixing) insert consisting of a carrier based on a knitted fabric, wherein the knitted fabric is produced from at least two warp thread systems, at least one of which is incorporated into the knitted fabric as a partial weft and contains staple fiber yarns. One side of the knitted fabric is provided with an adhesive layer. The resulting insert has very high elasticity in the longitudinal, transverse, and diagonal directions and is particularly cost-effective to produce. Furthermore, it is characterized by a very soft, textile feel and good appearance.