Gradient Missed-Stitch Knit Apparel for Airflow and Body Separation
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Solution Overview
Problem
Existing knit apparel often requires post-processing material treatments to create zonal venting and standoff features, which can be cumbersome and limit design flexibility.
Innovation Solution
Integrally knit structures, such as nodes and apertures, are formed directly during the knitting process using various stitch types and yarn combinations to create zonal venting and standoff zones, allowing for seamless construction and customizable airflow and separation from the body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If post-processing material treatments are used to create zonal venting and standoff features, then airflow and separation from body are improved, but manufacturing complexity and time are increased
Solution Approach 1:
The patent applies preliminary action by incorporating airflow zones and standoff features directly into the knitting process itself, rather than adding them through post-processing treatments. The knitting machine creates these features as integral parts of the garment construction, eliminating the need for separate manufacturing steps and reducing overall process complexity.
Solution Approach 2:
The patent merges the creation of structural features (airflow zones and standoff) with the base garment knitting process. By combining these functions into a single integrated knitting operation using programmed needle selection and yarn feed control, the manufacturing process becomes more efficient and less complex than sequential post-processing methods.
2Adaptability or versatility
If post-processing material treatments are applied to create zonal venting and standoff features, then garment functionality is improved, but production time and efficiency are reduced
Solution Approach 1:
The airflow zones and standoff features are created during the primary knitting process itself, performing the required action in advance rather than through subsequent treatments. This preliminary integration of functional features into the base construction eliminates multiple production steps and significantly improves manufacturing efficiency.
Solution Approach 2:
The knitting process continues uninterrupted to create both the garment structure and the functional airflow/standoff features simultaneously. The programmed knitting machine maintains continuous production flow without stopping for separate post-processing operations, thereby maximizing productivity while delivering versatile garment functionality.
3Ease of operation
If traditional post-processing techniques are used to create standoff nodes and venting features, then material separation and airflow are achieved, but design flexibility and customization are limited
Solution Approach 1:
The knitting machine's programmed needle selection and yarn feed control systems provide dynamic adaptability, allowing airflow zones and standoff features to be customized for different garment styles, sizes, and performance requirements. This digital programming approach enables rapid design changes and customization without requiring different physical tooling or processing methods.
Solution Approach 2:
The integrated knitting system serves multiple functions simultaneously: creating the garment structure, forming airflow zones, and producing standoff features. This universal approach allows a single manufacturing process to deliver customized designs with varied functionality, greatly enhancing design flexibility compared to specialized post-processing techniques.
Data Source
AI summary
Knit apparel formed using knitted structures and yarn content to create zonal properties provided. In aspects, garments, such as lower-body garments, have gradient missed-stitch structures creating protrusions on the external surface of the garment. Each gradient missed-stitch structure has at least a first missed-stitch segment and a second missed-stitch segment. The first missed-stitch segment is formed by a first set of float stitches along a first plurality of courses, and the second missed-stitch segment is formed by a second set of float stitches along a subset of the first plurality of courses. There may be additional missed-stitch segments formed across different quantities of courses such that the gradient missed-stitch structures are each tapered.