Engineered Knitted Garment With Seamless Compression Zones

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Solution Overview

Problem

Current compression garments often have seams that cause chafing and require significant fabric waste and labor, leading to increased manufacturing costs.

Innovation Solution

An engineered knitted garment with integrated compression zones, utilizing a raschel knitting machine with two jacquard guide bars to seamlessly knit different compression zones with varying levels of compression and breathability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If compression garments are made by cutting and sewing fabrics with different structural properties, then different levels of compression can be provided, but seams are created that cause chaffing

Engineering Contradiction:

Improvecompression levelsVSAvoidchafing

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple fabric pieces with different compression properties into a single seamless knitted garment. The raschel knitting machine knits different zones with varying compression levels (e.g., 20-40 mmHg at calves, 10-20 mmHg at knees) in one continuous process, eliminating seams and associated chafing while maintaining differentiated compression support.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies local quality by creating specific compression zones within the garment that provide different compression levels at different body locations. The knitted garment incorporates high compression zones (calves, ankles) and low compression zones (knees, thighs) through varied stitch patterns and yarn compositions in specific areas during the knitting process.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If compression garments are made by cutting and sewing multiple fabric pieces, then different compression zones can be achieved, but fabric waste increases

Engineering Contradiction:

Improvecompression zonesVSAvoidfabric waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent combines multiple compression zones into a single continuously knitted fabric structure. The raschel knitting machine produces the entire garment or large sections in one piece with integrated compression zones, eliminating the need to cut and discard excess fabric from multiple separate pieces, thereby significantly reducing fabric waste.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If compression garments are made by cutting and sewing multiple fabric pieces, then different compression zones can be created, but labor and manufacturing costs increase

Engineering Contradiction:

Improvecompression zonesVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges the production of multiple compression zones into a single knitting operation. The raschel knitting machine is configured with multiple guide bars that simultaneously control different stitch patterns and yarn selections to create various compression zones in one continuous process, eliminating multiple cutting, sewing, and assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary action by programming the raschel knitting machine with pre-set patterns for different compression zones before production begins. The machine automatically adjusts yarn feeding, stitch formation, and tension control for each zone during knitting, eliminating the need for post-production assembly and quality checking of multiple separate components.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If uniform compression is applied throughout the garment, then manufacturing is simpler, but mobility is restricted in areas requiring greater movement

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmobility

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250288466A1Engineered knitted garment having integrated compression zones

Publication Date: 2025.09.18 LULULEMON ATHLETICA CANADA INC

AI summary

Examples of an engineered knitted garment with a number of integrated compression zones are disclosed. The engineered knitted garment may be a pair of tights having a first compression zone located at the calves, a second compression zone located at the knees, and a third compression zone located at the waist. The compressive moduli of the compression zones may be different to provide higher compression in areas where greater support is required (e.g., at the calves) and lower compression in areas where greater mobility is required (e.g., at the knees).