Injection Molded Knit Panels With Integrated Solid Locations
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Solution Overview
Problem
Existing knitted articles require additional support or reinforcement to achieve rigidity and maintain their shape, which limits their design flexibility and functionality, and they can unravel if stitches are detached, compromising their structural integrity.
Innovation Solution
Injection molded panels with a knit-like surface are developed, featuring a base layer and a tactile layer that mimics knitted patterns, providing axial stability and allowing for the creation of stand-alone, three-dimensional articles without external anchoring structures, where intersecting strands form solid molded locations and gaps between strands maintain the knit pattern's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If knitted articles are made from yarns and stitches, then they achieve a flexible, patterned surface, but they require additional support structures or hardening agents to provide rigidity and maintain shape
Solution Approach 1:
The patent merges the knitted surface pattern with a rigid backing layer into a single integrated panel structure. The knit-like surface is formed by injection molding over a rigid backing, eliminating the need for separate anchoring structures or hardening agents that would otherwise be required to maintain the shape of knitted articles.
Solution Approach 2:
The patent uses composite construction by combining a knit-like surface layer with a rigid backing layer in a single injection molded panel. This composite structure provides both the flexible, patterned appearance of knitted materials and the rigidity of solid backing, without requiring additional support structures.
2Strength
If knitted articles are reinforced with fabric stiffeners, glues, or epoxy, then they achieve sufficient rigidity, but the structure becomes more complex and requires additional materials
Solution Approach 1:
The rigid backing layer is integrated directly into the panel structure during injection molding, merging the reinforcement function with the base panel construction. This eliminates the need for separate fabric stiffeners, glues, or epoxy reinforcements that would increase structural complexity.
3Stability of the object's composition
If knitted articles use tight knitting with thick yarns, then they maintain a tight configuration, but gaps between stitches remain visible and the material becomes less flexible
Solution Approach 1:
The patent applies local quality by creating a knit-like surface pattern only on the visible face of the panel, while the internal structure consists of solid molded material. This allows the surface to exhibit tight, gap-free appearance characteristics without sacrificing the flexibility and structural integrity of the molded panel.
4Ease of operation
If knitted panels are detached or torn, then individual stitches separate, but this causes further unraveling and compromises structural integrity
Solution Approach 1:
The patent creates a copy of the knitted appearance through injection molding rather than using actual knitted material. The molded panel replicates the visual and tactile characteristics of knitted fabric while maintaining the structural integrity of solid molded material, preventing unraveling even when damaged.
Data Source
AI summary
Provided is a molded panel having at least one surface resembling a knit-like pattern, said panel comprising a plurality of stitches at least partially interconnected through connecting members wherein at locations where the stitch strand and the connecting member intersect they form together an integrated, solid molded material location and wherein the panel comprises through going apertures extending therethrough.