Tubular Knit Printing on Expanded Loops and Channels
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Solution Overview
Problem
Knit fabrics are challenging to print on due to their three-dimensional configuration, which makes it difficult to retain and register designs, and the appearance of printed designs is often diminished by ink being applied below the visible surface, becoming visible during fabric flexing and stretching.
Innovation Solution
A tubular knit textile with interlocked loops and channels is printed using a specialized printer system with a tubular platen that retains and registers the fabric in an expanded state, allowing ink to be applied to the external side, including the top portions and base channel portions, ensuring durable and visible designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If knit fabric is printed in its normal three-dimensional state, then the printing process is simpler, but the printed design becomes distorted and invisible when the fabric flexes or stretches
Solution Approach 1:
The patent applies dynamics by transitioning the knit fabric from its normal three-dimensional state to a two-dimensional flattened state during printing. The fabric is dynamically reconfigured from a volumetric, flexible structure to a planar, stable structure that maintains print integrity. This state transformation allows the print to be applied on a stable surface while preserving the fabric's inherent flexibility for comfort.
Solution Approach 2:
The patent changes key physical parameters of the knit fabric during the printing process. The fabric's dimensional configuration is altered from 3D to 2D, and its mechanical state is modified from flexible to stable. These parameter changes enable high-resolution printing while maintaining the fabric's comfort properties, as the fabric returns to its natural flexible state after printing.
2Manufacturing precision
If knit fabric is flattened to two dimensions for printing, then print quality improves, but the fabric loses its natural flexibility and comfort
Solution Approach 1:
The patent uses dynamics to temporarily flatten the knit fabric for printing while preserving its ability to return to the flexible three-dimensional state. The flattening is a transient state change that occurs during the printing process only, allowing high-quality print application without permanently compromising the fabric's elasticity and comfort properties.
Solution Approach 2:
The patent applies preliminary action by pre-flattening the knit fabric to two dimensions before printing occurs. This preparatory step creates a stable, planar surface that receives high-resolution prints accurately. After printing, the fabric is allowed to return to its natural three-dimensional flexible state, combining print quality with fabric comfort.
3Reliability
If ink is applied below the visible surface of the fabric, then the print becomes more durable, but it becomes visible and distracting when the fabric stretches
Solution Approach 1:
The patent applies dynamics by printing on the stable, flattened two-dimensional surface of the fabric rather than on the flexible three-dimensional surface. This dynamic approach to surface selection ensures that ink is deposited on a stable plane where it adheres properly and remains durable, while avoiding the problem of underlying yarns becoming visible during fabric movement.
4Manufacturing precision
If the fabric is expanded during printing, then ink can be applied to external surfaces only, but the printing setup becomes more complex
Solution Approach 1:
The patent uses dynamics to expand the knit fabric to a stabilized, larger two-dimensional configuration during the printing process. This dynamic expansion creates a stable printing surface that allows for precise ink application to external surfaces only. The expanded state maintains structural integrity while providing adequate surface area for high-resolution printing.
Data Source
AI summary
An article of apparel including a tubular knit textile region is provided, as well as an apparel printing system for printing on regions of the tubular knit textile region and related methods. The article of apparel can include a tubular knit textile region having an internal side and an opposite external side configured to be exposed during use, a plurality of yarns in an arrangement of interlocked loops forming parallel rows and channels therebetween, and a printed ink design on its external side. The printed ink design can be formed from ink applied to the parallel rows of loops and to the channels. An apparel printing system for printing on the article of apparel can include a textile printer having a print head and a tubular platen that includes features on the platen surface to retain and register the tubular knit textile on the platen surface during printing.