Integral Loop Spacer Fabric for Reliable Fastener Integration

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Solution Overview

Problem

Existing spacer fabrics and hook-and-loop fasteners are separate entities, leading to issues like delamination, wear, and loss of breathability when combined through lamination, with no known method to integrate them into a single fabric providing both functionalities during the knitting process.

Innovation Solution

A three-dimensional spacer fabric is created with interknitted layers, including a first layer, a second interconnecting layer, and a third layer with integral, exposed loops that function as a hook-and-loop fastener, eliminating the need for affixation and integrating the benefits of both fabric types into a single unitary fabric.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hook-and-loop fasteners are affixed to spacer fabric using adhesive or mechanical stitching, then the fastener functionality is achieved, but delamination or detachment occurs and the fabric properties are compromised

Engineering Contradiction:

Improvefastener attachment reliabilityVSAvoidfabric structure integrity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent merges the spacer fabric and hook-and-loop fastener into a single integrated knitted structure. The looped yarns are incorporated directly into the fabric during the knitting process, eliminating the need for separate affixation steps. This integration ensures that the fastener loops are permanently embedded in the fabric matrix, preventing delamination or detachment while maintaining fabric integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The looped yarns are prepared and positioned within the knitting machine before the fabric is produced. The loops are formed during the knitting process itself, rather than being added afterward. This preliminary incorporation of the fastener elements into the fabric structure during manufacturing prevents subsequent attachment failures.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If separate looped fabric is laminated to spacer fabric, then hook-and-loop functionality is achieved, but breathability is reduced and fabric properties are changed

Engineering Contradiction:

Improvefastener functionalityVSAvoidbreathability reduction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of laminating separate fabrics, the patent combines the spacer fabric structure with looped yarns integrated into the same knitted body. The looped yarns are distributed throughout the fabric matrix, allowing air and moisture vapor to pass through the open spacer structure while providing hook-and-loop functionality. This eliminates the breathability barrier created by adhesive lamination.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If looped fabric is used as a separate affixed component, then hook-and-loop fastening is achieved, but the loops deteriorate or wear from use

Engineering Contradiction:

Improvefastener functionalityVSAvoidloop durability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The looped yarns are embedded within the knitted fabric matrix during manufacturing, which provides structural support and protection to the loops before they are subjected to use. The surrounding fabric structure acts as a cushioning matrix that prevents the loops from being pulled or degraded by hooked elements, thereby extending their service life.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Adaptability or versatility

If two separate fabrics are laminated together, then both spacer and looped fabric functionalities are achieved, but the properties of each fabric are changed and diminished

Engineering Contradiction:

Improvedual fabric functionalityVSAvoidfabric property retention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the spacer fabric and looped fabric into a single integrated knitted structure where both functionalities coexist within the same fabric body. The spacer structure provides breathability and insulation, while the integrated looped yarns provide fastener functionality. This unified structure eliminates the property changes and diminishments that occur when separate fabrics are laminated together.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7426840B2Spacer fabric with integral, exposed loops and method of making

Publication Date: 2008.09.23 SYTZ RONALD M

AI summary

A three dimensional spacer fabric including a unitary, integral spacer fabric formed from interknitted layers, including a first layer of fabric, a second interconnecting layer and a third layer of fabric, wherein the third layer further includes loops of yarn protruding outward with loop apex points providing a looped surface on one side of the fabric for functioning with hook-and-loop type fasteners, and methods of making said fabric.