Gradual Weaving Density Gradient in Apparel

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Solution Overview

Problem

Existing sports apparel with multiple zones for varying anatomic and athletic requirements is limited by uncomfortable stitching, weight addition, and weak spots due to sewing, which complicates production and fails to accurately match gradual changes in air permeability, thermal insulation, and moisture transport needs.

Innovation Solution

An article of apparel with gradually changing weaving density and yarn weight per unit length across distinct areas, eliminating the need for stitching by integrating these zones into a single unitary woven fabric, allowing for precise matching of anatomic and athletic requirements through controlled weaving density and yarn weight gradients.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate sheets are sewn together to provide different zones for varying anatomic and athletic requirements, then the article of apparel can accommodate different functional needs (air permeability, thermal insulation, moisture transport), but the stitching areas become uncomfortable, cause abrasions, and create weak spots

Engineering Contradiction:

Improvefunctional zonesVSAvoidstitching discomfort and abrasions

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple separate functional sheets into a single unitary woven fabric where different zones are created by varying weaving density and yarn properties within the same continuous material. This eliminates the need for stitching between separate sheets, thereby removing the harmful effects of stitching while preserving the functional zone differentiation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies local quality by creating zones with different weaving densities and yarn weights within the unitary fabric to provide location-specific functional properties (higher air permeability in high-sweat areas, lower permeability in low-sweat areas) without requiring separate sheets and their associated stitching.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If separate sheets are used to create different functional zones, then varying anatomic and athletic requirements can be met, but the production process becomes complicated and time-consuming due to additional sewing steps

Engineering Contradiction:

Improvefunctional zonesVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent combines multiple separate manufacturing steps (cutting separate sheets, positioning them, and sewing them together) into a single weaving process that produces the complete multi-zone garment in one continuous operation, thereby dramatically improving production efficiency while maintaining functional zone differentiation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary action by incorporating all zone differentiations directly into the weaving process itself, rather than adding zones through post-weaving assembly steps. The functional zones are built-in during the primary manufacturing process, eliminating subsequent sewing operations.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If separate sheets are sewn together to provide different functional zones, then anatomic and athletic requirements can be addressed, but stitching adds weight and creates weak spots for tearing

Engineering Contradiction:

Improvefunctional zonesVSAvoidtear resistance

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent merges separate sheets into a unitary fabric structure where all zones are interconnected through continuous yarns throughout the material. This eliminates stitching joints that would otherwise serve as weak points for tearing, resulting in a garment with uniform and superior tear resistance across all zones.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If separate sheets are used to create different functional zones, then varying anatomic and athletic requirements can be met, but the article of apparel becomes heavier due to additional stitching material

Engineering Contradiction:

Improvefunctional zonesVSAvoidapparel weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent combines multiple separate sheets and their associated stitching materials into a single unitary woven fabric where zone differentiations are achieved through variations in weaving density and yarn properties rather than through physical separation and joining. This eliminates the weight of stitching threads and hardware while preserving functional zone differentiation.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11821116B2Article of apparel

Publication Date: 2023.11.21 ADIDAS AG

AI summary

The present invention concerns an article of apparel including: a first woven area, where the first woven area includes a first weaving density and a first yarn weight per unit length; a second woven area arranged adjacent to the first woven area, where the second woven area includes a second weaving density and a second yarn weight per unit length; and a third woven area arranged adjacent to the second woven area, where the third woven area includes a third weaving density and a third yarn weight per unit length. The second weaving density in the second woven area changes gradually from the first weaving density to the third weaving density and/or the second yarn weight per unit length in the second woven area changes gradually from the first yarn weight per unit length to the third yarn weight per unit length.