Flat-knit Bra with Zonal Yarn Strength and Integrated Edging
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Solution Overview
Problem
Conventional bra manufacturing methods often result in material waste and require additional textile structures for finishing, which can be cumbersome and inefficient in creating seamless, supportive garments with optimal comfort and functionality.
Innovation Solution
The development of a flat-knit bra that integrates zonal support structures through varying yarn strengths and stitch sequences, allowing for seamless construction and minimal seaming, with finished edges that eliminate the need for surrounding textile structures, enabling efficient production and enhanced wearer comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional bra manufacturing methods are used, then the bra structure can be completed, but material waste is generated and additional textile structures are required for finishing
Solution Approach 1:
The patent combines the bra construction process with the edging/finishing process into a single flat-knitting operation. The edging elements are integrated directly into the bra structure during knitting, eliminating the need for separate finishing steps and reducing material waste by avoiding the removal of surrounding textile structures.
Solution Approach 2:
The flat-knitting machine automatically creates finished edges with edging elements as part of the knitting process itself. The edging elements self-attach to the bra structure during knitting, eliminating the need for separate attachment operations and reducing manual intervention.
2Loss of time
If conventional bra manufacturing with surrounding textile structures is used, then the bra can be constructed, but assembly time is increased due to additional seaming and finishing steps
Solution Approach 1:
Multiple functions (bra construction, edging, finishing) are merged into a single flat-knitting process. The edging elements are created and attached simultaneously with the bra structure, eliminating sequential operations and reducing total assembly time.
Solution Approach 2:
The flat-knitting machine performs multiple functions: constructing the bra structure, creating edging elements, and finishing the edges all in one operation. This multi-functionality reduces the number of separate manufacturing steps required.
3Adaptability or versatility
If zonal support structures with varying yarn strengths are integrated, then customized fit and support are achieved, but the knitting process complexity increases
Solution Approach 1:
The patent applies different yarn strengths and edging element characteristics to specific zones of the bra based on local support requirements. High-strength yarns and rigid edging elements are used in high-support zones, while softer materials are used in comfort zones, achieving customized fit through localized material properties.
Data Source
AI summary
Aspects of a flat-knit support garment for an upper torso are provided. The flat-knit support garment may include a bra structure having a flat-knit bra material that includes a cup zone, a body zone, a wing zone, a strap zone, and a chestband zone. In some instances, a perimeter of the flat-knit bra comprising a neck opening and armhole openings includes a finished edge treatment corresponding to a high stretch modulus, covered yarn. Such finished edges are generated in seamless construction with the unitary, flat-knit structure of the flat-knit support garment for an upper torso. The flat-knit characteristics of the support garment for an upper torso may correspond to one or more of a flat-knit stitch sequence, a yarn type, and/or a finishing treatment.