Seamless Knitted Brassiere with Integrally Knit Shoulder Straps
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Solution Overview
Problem
Seamless knitted brassieres lack dimensional stability due to the absence of seams, which can lead to distortion and reduced strength, and there is a need for improved strap and brassiere stability.
Innovation Solution
A seamless knitted brassiere is designed using tubular knitted fabric with integrally knit shoulder straps, welts, and run guards to enhance stability, featuring specific knit constructions and edge finishes that prevent unraveling and provide cushioning, formed using a circular knitting machine with adjustable yarn feeders and stitch patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If seamless knitted brassieres are made without seams, then manufacturing simplicity and design flexibility are improved, but dimensional stability and strength deteriorate due to distortion and lack of structural support
Solution Approach 1:
The brassiere is divided into distinct functional zones with different knit constructions: the cup portion uses 1x1 knit-miss stitches for shape maintenance, while the band portion uses 1x2 knit-miss stitches for flexibility. This segmentation allows each area to perform its specific function optimally while maintaining overall seamless construction.
Solution Approach 2:
Different regions of the brassiere are assigned different knit patterns and stitch densities tailored to their specific functional requirements. The cup area has tighter knitting for structural support, while the band area has more open knitting for comfort and flexibility, creating local quality variations that enhance overall dimensional stability.
2Extent of automation
If seams are removed to create seamless garments, then ease of manufacture and automation are improved, but strength and durability deteriorate due to absence of sewn seams that provide structural support
Solution Approach 1:
The shoulder straps are integrally knit into the brassiere body as a continuous piece rather than being separate components sewn together. This merging of the strap and body into a single knitted structure eliminates the need for separate sewing operations while maintaining structural strength through the continuous knit construction.
3Ease of manufacture
If openings are formed in a single fabric to create seamless design, then manufacturing simplicity is improved, but dimensional stability deteriorates due to distortion and inability to maintain shape
Solution Approach 1:
The knit construction parameters are varied across different regions: the cup portion uses 1x1 knit-miss stitches with higher density for shape maintenance, while the band portion uses 1x2 knit-miss stitches with lower density for flexibility. This parameter change allows the single fabric to maintain different properties in different areas, preventing distortion while preserving the seamless design.
Data Source
AI summary
A seamless knitted brassiere includes a body encircling portion and at least one shoulder strap knit therein. The shoulder strap has a length and a first welt along the length. The shoulder strap also has a second welt along the length and adjacent the first double welt. The shoulder strap also has a novel run guard adjacent either of the two welts.