Four-Layer Knitted Fabric with Hidden Conductive Heating Layer
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Solution Overview
Problem
Existing heat-generating textile products often expose electrically conductive yarns, leading to skin burns and discomfort, and rely on specialized batteries, reducing user convenience.
Innovation Solution
A weft knitted fabric with a four-layer structure where the electrically conductive layer is hidden beneath non-conductive layers, forming uniformly distributed protrusions that generate heat when energized, using a general-purpose power supply via a three-port USB connector with adjustable power control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrically conductive yarn is used to generate heat in the textile product, then heat generation function is achieved, but the conductive yarn is exposed to the fabric surface causing skin burns and discomfort
Solution Approach 1:
The conductive yarn is nested within multiple fabric layers (first, second, and third layers) rather than being exposed on the surface. The heating element is embedded inside the textile structure like a nested doll, with non-conductive outer layers providing protection while the conductive inner layer generates heat, thus preventing skin contact and burns.
Solution Approach 2:
Non-conductive fabric layers serve as intermediary barriers between the conductive heating yarn and the user's skin. These intermediary layers transfer the heat function while blocking direct contact with the conductive element, preventing harmful effects while maintaining the heating function.
2Temperature
If specialized batteries are used in heat-generating textile products, then heat generation function is achieved, but user convenience and comfort are reduced due to non-general-purpose requirements
Solution Approach 1:
The textile product is designed to work with universal general-purpose batteries rather than requiring specialized battery types. This universality allows users to use commonly available batteries, greatly improving convenience and comfort while maintaining the heat generation function through the multi-layer protective structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fabric provides a comfortable, heat-generating zone without direct exposure to conductive yarns and can use standard batteries, offering improved user safety and convenience with adjustable heat settings.
Implementation Method 1
the second fabric layer is electrically conductive such that when the second fabric layer is electrically energized, air trapped inside the protrusions is heated up, causing the knitted fabric to generate heat
Data Source
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AI summary
A knitted fabric having a heat generating function has a four-layer structure and can be knitted by a flat knitting machine. Knit stitching is used to knit first and second layers such that the second layer is fully covered under the first layer. Tuck stitching is used to knit the third layer such that one stitch is made to the third layer per a preset number of stitches made to each of first and second layers. Knit stitching is used to knit the fourth layer. After knitting, the fabric is soaked with water and spin-dried to form protrusions, spatially distributed as a centered rectangular lattice, on fabric surface. The second layer is electrically conductive for generating heat and is hidden inside the fabric. This layer is not easily hooked by a user during use and cleaning. The fabric is elastic and soft, and provides a comfortable feeling to the user.