Gussetless Dance Tight Seamless Circular Knitting
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Solution Overview
Problem
Traditional dance tights with gussets are uncomfortable and visible under leotards and costumes, and their construction involves complex processes with multiple seams, leading to potential tearing and inadequate stomach support.
Innovation Solution
A gussetless dance tight is created using circular knitting with a higher density area at the crotch transition and a thicker waistband, eliminating vertical seams and gather stitches for a smoother, more supportive design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional gussets are used in dance tights, then the crotch area has adequate coverage and structure, but the gusset becomes visible under leotards and costumes causing discomfort and aesthetic issues
Solution Approach 1:
The patent removes the traditional gusset component entirely from the dance tight construction. Instead of using a separate gusset piece that creates visibility and comfort issues, the invention integrates the crotch area directly into the main body of the tight through seamless circular knitting, extracting the problematic element while maintaining functional coverage
Solution Approach 2:
The patent merges the gusset area with the main body of the tight by using continuous circular knitting without separate pieces or seams. The transition from the main body to the leg openings is integrated into a single seamless tube construction, combining what were traditionally separate components into one unified structure
2Reliability
If traditional multiple-seam construction is used, then the tight can be manufactured with standard processes, but the vertical seams create potential tearing points and reduce durability
Solution Approach 1:
The patent combines multiple separate knitting pieces into a single continuous tube using circular knitting technology. This eliminates the need for separate seam joining operations while maintaining the ability to manufacture the tight efficiently through a streamlined single-process approach
Solution Approach 2:
The patent replaces the mechanical seam joining system with a knit-structure-based transition system. Instead of using needles and thread to join separate pieces, the invention uses variations in knitting density and stitch patterns to create smooth transitions between different areas of the tight, eliminating mechanical seams entirely
3Ease of operation
If gather stitches are used to create the crotch area, then the tight can be formed from a single tube, but the gather stitches create visible lines and discomfort under clothing
Solution Approach 1:
The patent applies different knitting densities to different local areas of the tight. The crotch area uses a higher density knit pattern that provides structural support and smooth appearance, while the leg areas use a lower density pattern for flexibility and comfort, creating local variations in material properties without visible lines
Solution Approach 2:
The patent changes the knitting parameters (stitch density, needle selection, tension) in the crotch area to create a higher density region that eliminates the need for gather stitches. This parameter change allows the fabric to transition smoothly from the main body to the legs without creating visible lines or discomfort
4Strength
If a thin waistband is used, then the tight is more flexible and comfortable, but it provides inadequate stomach support
Solution Approach 1:
The patent creates a waistband with locally increased density and thickness compared to the rest of the tight. This localized variation in material properties provides enhanced stomach support where needed while maintaining flexibility and comfort in the leg areas, resolving the contradiction between support and comfort
Data Source
AI summary
A gussetless dance tight is disclosed. The gussetless dance tight comprises a legwear portion created from a single tube without any vertical seams. The legwear portion comprises an upper portion, two leg portions, and a transition between the two leg portions where the two leg portions meet. The legwear portion comprises a higher density area at the transition. The higher density area transitions to the upper portion using circular knitting without a gather stitch. The gussetless dance tight also comprises a waistband coupled to the upper portion.