Fabric With Integral Channels Reducing Production Time
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Solution Overview
Problem
Conventional methods for creating fabrics with channels are complex and time-consuming, leading to increased production costs and higher prices for consumers.
Innovation Solution
A fabric is produced with an upper layer and a lower layer that connect partially to form integral connecting segments and channels, using a sewing step to form the layers and a connecting step to integrate the channels, reducing production time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-step sewing methods are used to form channels in fabric, then the fabric structure can be created, but the production process becomes complex and time-consuming, leading to increased costs
Solution Approach 1:
The patent combines multiple separate sewing operations into a single integrated knitting process. The channel formation is merged with the fabric construction itself, allowing channels to be created during the primary fabric formation rather than through subsequent separate sewing steps, thereby reducing production time and process complexity
Solution Approach 2:
The channel structure is formed preliminarily during the knitting process before any additional sewing or assembly operations. By creating the channels in advance as part of the fabric structure itself, the need for later time-consuming sewing operations is eliminated
2Manufacturing precision
If conventional multi-step sewing methods are used to form channels in fabric, then the fabric structure can be created, but the number of production steps increases, leading to higher manufacturing costs
Solution Approach 1:
The patent merges channel formation with the fabric knitting process into a single operation. Instead of using multiple separate sewing machines and operations, the channel structure is integrated into the knitting mechanism itself, reducing device complexity while maintaining precision through the unified process
Solution Approach 2:
The knitting machine is designed to perform multiple functions simultaneously: it creates the fabric structure and forms the channels in a single operation. This multi-functionality eliminates the need for separate dedicated channel-forming equipment, reducing overall device complexity
Data Source
AI summary
A fabric has an upper layer and a lower layer. The lower layer connects partially to the upper layer to integrally form multiple connecting segments formed on the upper layer and the lower layer. The at least one channel is formed on the upper layer and the lower layer and is formed respectively between adjacent connecting segments. The fabric is produced by a sewing step and a connecting step. The sewing step comprises sewing multiple raw fibers to respectively form the upper layer and the lower layer. The connecting step comprises connecting partially the upper layer to the lower layer by fiber to integrally form the connecting segments and the at least one channel. Thus, time and a cost of a production of the fabric can be reduced to relieve customers' burdens.