Knit Spacer Fabric Structure for Insulation Without Fiber Shedding
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Solution Overview
Problem
Existing insulating fabrics for garments suffer from fiber loss during washing, leading to microfiber pollution and reduced insulation performance, and the brushing process can cause fiber breakage and environmental pollution.
Innovation Solution
A knit spacer fabric with upper and lower fabric layers connected by zipper and linking connecting yarns, forming parallel columns with controlled spacing and stitching patterns to minimize fiber loss and enhance insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fleece fabric is raised by mechanical brushing to improve insulation performance, then the fabric achieves higher loft and better insulation, but fiber breakage occurs and microfiber pollution is generated
Solution Approach 1:
The patent removes the mechanical brushing step from the fabric production process. Instead of brushing the fleece fabric to raise the fibers, the invention uses a knit spacer structure with air pockets that provides insulation without the harmful brushing process, thereby eliminating fiber breakage and microfiber pollution at the source
Solution Approach 2:
The patent changes the structural parameters of the fabric by creating a knit spacer construction with specific column spacing and air pocket dimensions. This structural parameter change provides the necessary insulation performance without requiring mechanical brushing, thus avoiding fiber damage and microfiber release
2Temperature
If fleece fabric is brushed to increase loft for better insulation, then insulation performance improves, but fiber loss occurs during washing and insulation deteriorates over time
Solution Approach 1:
The patent eliminates the mechanical brushing process that causes fiber damage. The knit spacer fabric achieves its insulation performance through its structural air pockets rather than through a raised fiber surface, removing the root cause of fiber loss during washing and subsequent insulation deterioration
Solution Approach 2:
Instead of creating insulation by raising and brushing fibers to increase surface loft, the patent inverts the approach by creating insulation through controlled air pockets within a stable knit spacer structure. This inverted methodology provides insulation without compromising fiber integrity or retention
3Temperature
If traditional fleece fabric is used to achieve insulation, then thermal performance is improved, but fabric weight increases
Solution Approach 1:
The patent utilizes the knit spacer fabric's inherent porous structure with air pockets between the upper and lower fabric layers. These air pockets provide thermal insulation without requiring additional heavy materials, achieving high insulation performance with low fabric weight through the strategic use of air as an insulating medium
Data Source
AI summary
A knit spacer fabric contains an upper fabric layer with a plurality of upper yarns and forming the upper surface of the knit spacer fabric and a lower fabric layer with a plurality of lower yarns and forming the lower surface of the knit spacer fabric. The knit spacer fabric further contains a plurality of zipper connecting yarns and a plurality of linking connecting yarns. The upper fabric layer contains a plurality of spaced apart parallel knitted upper columns, each formed from at least two upper yarns knitted together and the upper yarns from one column are not knitted with the upper yarns of adjacent columns. At least a portion of the zipper connecting yarns stitch together two adjacent upper columns and at least a portion of the linking connecting yarns stitch together in one lower and one upper column.