Fabric Buckle Units via Integrated Warp Knitting
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Solution Overview
Problem
Current methods for fixing buckle structures on fabrics, such as hot melt adhesion or sewing, result in a complicated manufacturing process and unstable fabric structures, which are prone to damage when pulled.
Innovation Solution
A fabric with buckle units is designed as a three-layer structure, where the buckle yarn is woven back and forth in the surface layer to form buckle units that protrude from the fabric, while the middle and bottom layers provide stability through warp and weft knitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot melt adhesion or sewing is used to fix the buckle on the fabric, then the buckle structure can be attached to the fabric, but the manufacturing process becomes complicated and the fabric structure becomes unstable
Solution Approach 1:
The buckle yarn is integrated directly into the fabric body during the knitting process, merging the buckle structure with the fabric structure. This eliminates separate attachment steps (hot melt adhesion or sewing) and creates a unified, stable structure where the buckle yarn forms part of the fabric's inherent architecture rather than being an external component.
Solution Approach 2:
The buckle yarn is pre-integrated into the fabric body during the knitting process before the fabric is completed. This preliminary integration ensures that the buckle structure is already stabilized within the fabric's framework before any subsequent manufacturing steps, preventing structural instability during later handling and use.
2Strength
If the buckle is directly fixed on the fabric by hot melt adhesion or sewing, then the buckle can be attached, but the fabric structure is prone to damage when pulled
Solution Approach 1:
The buckle yarn is merged with the fabric body through integrated knitting, creating a unified structure where the buckle and fabric share the same structural framework. This integration distributes pulling forces across the entire fabric structure rather than concentrating stress at attachment points, thereby preventing fabric damage when the buckle is pulled.
3Reliability
If a three-layer structure with middle and bottom layers is added to provide stability, then the fabric structural stability improves, but the device complexity increases
Solution Approach 1:
The fabric body is segmented into three functional layers: a surface layer for the buckle units, a middle layer for structural support, and a bottom layer for additional stability. This segmentation allows each layer to perform its specific function while collectively providing enhanced overall stability without requiring complex external components or assembly procedures.
Solution Approach 2:
The fabric employs a composite multi-layer structure where different layers work together to provide both stability and functionality. The combination of surface layer, middle layer, and bottom layer creates a composite fabric system that achieves high structural stability through the synergistic interaction of its components rather than through single-material complexity.
Data Source
AI summary
A fabric with buckle units includes a fabric body and a buckle yarn. The fabric body includes a surface layer, a bottom layer and a middle layer. The surface layer is knitted by a surface knitting unit in a warp knitting manner. The middle layer is disposed and connected between the surface layer and the bottom layer. The buckle yarn is woven back and forth in the surface layer of the fabric body to form a plurality of buckle units, which protrude from at least one side of the fabric body.