Knit Fabric Adhesion via Elastic Floats
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Solution Overview
Problem
Existing methods for producing knitted parts, such as bandages, require additional adhesive tapes or applications, which are complex and inefficient for creating adhesion areas, especially on the side facing the skin.
Innovation Solution
A method involving a knitting machine with two opposite needle beds and a stitch transfer device to knit a basic fabric, transfer stitches, and use an elastic thread to form floats that create a defined adhesion area by pressing stitches into the fabric, eliminating the need for external adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional adhesive strip or appliqué is sewn or applied to the knitted fabric, then adhesion to the skin is improved, but the production complexity and number of manufacturing steps increase
Solution Approach 1:
The invention merges the adhesive function with the knitted fabric itself by incorporating an elastic yarn directly into the knitting structure. This eliminates the need for separate adhesive strips or appliqués, as the adhesive properties are integrated into the fabric's construction through the elastic yarn that protrudes on the wrong side of the fabric.
Solution Approach 2:
The elastic yarn serves multiple functions simultaneously: it provides structural support as part of the knitted fabric, creates the adhesive area by protruding on the wrong side, and eliminates the need for separate adhesive components. This multi-functionality reduces production complexity while maintaining adhesion reliability.
2Productivity
If an elastic yarn is knitted in to form an adhesive area, then the number of manufacturing steps is reduced, but the uniformity and distribution of adhesion contact may be compromised
Solution Approach 1:
The invention applies local quality by having the elastic yarn protrude specifically on the wrong side of the fabric in defined adhesive areas, while the right side maintains the standard knitted structure. This localized differentiation ensures uniform adhesion contact where needed without compromising the overall fabric structure or uniformity of the adhesive distribution.
3Ease of manufacture
If stitches are transferred between needle beds and elastic thread is used to form floats, then adhesion area is created directly on the fabric, but the knitting process complexity increases
Solution Approach 1:
The invention applies preliminary action by transferring stitches between needle beds and forming the adhesive area with elastic yarn during the knitting process itself, before the fabric is completed and removed from the machine. This integrated approach creates the adhesive area as part of the base fabric construction, eliminating the need for separate adhesive application steps and simplifying the overall manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for a strong, evenly distributed adhesive contact on the skin side without external adhesives, ensuring good adhesion while preventing interference from adjacent stitches, thus simplifying the production of knitted parts with adhesive properties.
Implementation Method 1
an elastic yarn knitted in at least partially, wherein the base knit is formed in two surfaces and the elastic yarn is raised on the inside of the fabric in at least a part of the rows of stitches
Data Source
Figure 1a~1c
Figure 1d~1e
Figure 2
AI summary
Method for producing a knitted fabric, in particular a bandage, on a knitting machine comprising two needle beds (1, 2) arranged opposite each other and a stitch transfer device, characterised by the following steps: a) knitting a base fabric on both needle beds (1, 2); b) transferring individual stitches (8), hanging on spaced needles (5b) of rows of stitches of the first needled bed (1) forming the left-hand product side, onto opposing empty needles (6b) of the other second needle bed (2), c) casting off of needles (5a) of the first needle bed (1) occupied by tucks (7) or stitches and adjacent to needles (5b) which are free as a result of the transfer, by means of an elastic thread (4) with the formation of a float (11), d) transferring back the previously transferred stitches (8) onto the previous needles (5b), e) casting off of the transferred back stitches (8) and the stitches (10) knitted from the elastic threads (4) with the threads (3) forming the base fabric.