Flat-Knitted 3D Fabric Internal Support Structure
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Solution Overview
Problem
Existing flat-knitted three-dimensional fabrics with internal support structures face issues of protruding yarns compromising comfort and low surface density due to the limitations of double-needle bed flat knitting machines, which restrict the formation of mesh structures on both surface layers.
Innovation Solution
The use of a four-needle bed computerized flat knitting machine to knit alternate and fully-knitted single-sided stitches, with tuck stitches locking the support structure yarn, preventing it from puncturing the fabric surface, and enabling loop-transfer knitting to create mesh structures on both layers, thereby increasing surface density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If double-needle bed flat knitting machine is used to knit meshes on surface layers, then mesh structures can be formed, but surface density is low because idle needles are required for loop transfer
Solution Approach 1:
The patent transitions from a two-needle bed configuration to a four-needle bed configuration (front and back needle beds on both upper and lower levels), adding a vertical dimension to the knitting system. This dimensional expansion allows simultaneous knitting operations on multiple beds without requiring idle needles, thereby increasing surface density while maintaining mesh structure formation capabilities.
Solution Approach 2:
The knitting system is divided into four separate needle beds (front upper, back upper, front lower, back lower) that can operate independently or in coordination. This segmentation allows different regions of the fabric to be knitted with different stitch patterns simultaneously, enabling mesh structures on surface layers while fully utilizing all needles to increase overall surface density.
2Strength
If support structure yarn is used to connect fabric layers, then structural integrity is improved, but yarn protrusion occurs when fabric is pressed compromising comfort
Solution Approach 1:
The patent applies tuck stitches as a preliminary counteracting measure to prevent support structure yarn from protruding through the fabric surface when pressed. By incorporating these locking stitches in advance during the knitting process, the fabric is pre-equipped with structural features that resist yarn protrusion under compression, maintaining comfort while preserving structural integrity.
Solution Approach 2:
Alternate-knitted single-sided stitches are introduced in advance to lock the tuck loops formed by support structure yarn. This preliminary action ensures that before the fabric undergoes use and potential compression, the support yarn is already secured in position, preventing harmful protrusion while maintaining the intended structural support function.
3Object-affected harmful factors
If alternate-knitted single-sided stitches are added to lock tuck loops, then yarn protrusion is prevented, but fabric thickness increases
Solution Approach 1:
The patent applies alternate-knitted single-sided stitches selectively at specific locations where support structure yarn passes through the fabric, rather than uniformly throughout the entire fabric. This localized application locks tuck loops only where necessary to prevent yarn protrusion, minimizing the impact on overall fabric thickness while effectively addressing the harmful protrusion issue.
Data Source
AI summary
A flat-knitted three-dimensional fabric with an internal support structure, and the fabric is consisted of an upper surface layer, a lower surface layer, and a support structure yarn in a middle, wherein the upper surface layer and the lower surface layer comprise alternate-knitted single-sided stitches and fully-knitted single-sided stitches; the upper surface layer and the lower surface layer are connected by means of tuck knitting of the support structure yarn in the middle to form the integrally formed three-dimensional fabric with an internal support structure; and the alternate-knitted single-sided stitches are correspond to tuck loops formed by the support structure yarn and are used to lock the tuck loops formed by the support structure yarn in the middle, such that the support structure yarn will not puncture the surfaces of the fabric when the fabric is pressed.