Knitted Garment Collar With Segmented Flexible And Rigid Portions
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Solution Overview
Problem
Existing garment collars, particularly polo shirt collars, fail to maintain a secure fit during daily wear and intense movements without generating material waste and complexity in manufacturing.
Innovation Solution
A knitted garment collar with distinct flexible and rigid portions, utilizing arrow and structured mesh knitting techniques, eliminates the need for material cutting, ensuring better fit and stability during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a classic knitting technique (ribbing or structured knit) is used to manufacture a collar, then the collar has elasticity and comfort, but it does not provide adequate rigidity and stability during intense movements
Solution Approach 1:
The collar is divided into two distinct portions: a first portion made with flexible knit (1x1 ribbing) for comfort and adaptability, and a second portion made with rigid structured mesh knit for stability and support during movement. This segmentation allows each portion to fulfill its specific functional requirement independently.
Solution Approach 2:
Different knitting techniques are applied to different portions of the collar: the first portion uses 1x1 ribbing for flexibility where it contacts the neck, while the second portion uses structured mesh knitting for rigidity in the collar stand area. This local differentiation of material properties resolves the contradiction between flexibility and stability.
2Reliability
If woven fabric technique is used to manufacture a shirt collar, then the collar has good structure and rigidity, but the manufacturing process is time-consuming and generates material waste
Solution Approach 1:
The collar is manufactured as a single integrated knitted piece combining both flexible and rigid portions in one continuous knitting process, eliminating the need for separate manufacturing of collar strips and subsequent assembly operations required in woven fabric collar production.
Solution Approach 2:
The knitting machine automatically performs the entire collar manufacturing process including creating both flexible and rigid portions, shaping, and finishing in one operation, eliminating the need for external cutting and assembly operations that waste time and material.
3Ease of manufacture
If arrow knitting technique is used to give curved shape to collar ends, then material waste is eliminated and manufacturing is simplified, but the collar may lack adequate stability during intense movements
Solution Approach 1:
The collar is segmented into a first portion with curved ends made by arrow knitting for ease of manufacture, and a second portion made with structured mesh knitting that provides the stability needed during movement. The segmentation allows the curved shape benefit to coexist with movement stability.
Solution Approach 2:
The arrow knitting technique is applied locally to the first portion for curved shaping and manufacturing efficiency, while the structured mesh knitting is applied to the second portion for stability during movement, creating local quality differentiation that resolves the contradiction.
Data Source
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Figure 4~5
AI summary
The invention relates to a knitted garment collar (30), particularly for a polo shirt, comprising a first portion of flexible knit (31) including an outer longitudinal end (312) of substantially curved shape; a second portion of rigid structured knit (32), separate from the first portion and constituting the collar stand, including an outer longitudinal end (312) of substantially curved shape, this second portion being integral with the first portion; and a longitudinal folding axis of substantially curved shape of the first portion, such that this first portion folds along the longitudinal folding axis to cover a portion of the first portion and the entirety of the second portion. This collar further defines a height H1 between each outer longitudinal end at its central portion and a height H2 at its two lateral ends, with H1 equal to or greater than H2.The invention also relates to a method for manufacturing such a collar. The invention further relates to a garment comprising such a collar.