Integrally Knitted Compressive Article Seamless Tubular Connection
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Solution Overview
Problem
Existing articles with compressive effects, such as gloves, often lack comfort, aesthetics, and the ability to adapt to various sizes due to thick and uncomfortable seam connections and large mesh knit patterns, which also limit precision and suitability for smaller sizes.
Innovation Solution
The development of an integrally knitted article with fine gauge tubular elements, where each tubular element has an upper and open lower end, with specific anterior and posterior portions that overlap to create a seamless, thin, and comfortable connection, allowing for a wide range of sizes and precise pressure control using a rectilinear knitting machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tubular elements are knitted in a planed manner (one needle out of two or more) to connect two tubular elements, then the connection is achieved, but the mesh gauge becomes large (coarse) and the compressive precision is reduced
Solution Approach 1:
The connection between tubular elements is achieved by segmenting the knitting process into distinct phases: knitting the first tubular element, transferring stitches to the rear bed, knitting the second tubular element, and then connecting them through controlled stitch transfers. This segmentation allows fine gauge knitting throughout while achieving connection without resorting to planed knitting that would coarse the mesh.
Solution Approach 2:
The invention utilizes the spatial arrangement of front and rear needle beds in rectilinear knitting to solve the connection problem. By transferring stitches between beds and using the dimensional space created by bed movement, the patent achieves tubular element connection without compromising mesh fineness, effectively using the third dimension (bed depth/spatial arrangement) to resolve the contradiction.
2Ease of manufacture
If tubular elements are connected by overlapping multiple meshes (e.g., five meshes) to join the first and second tubular elements, then the connection is achieved, but the junction becomes thick and uncomfortable
Solution Approach 1:
The invention applies local quality by creating a minimal overlap connection (one or more single meshes) rather than uniform thick overlap throughout. The connection zone is locally optimized to be thin and comfortable while maintaining structural integrity, contrasting with the uniform thick overlap of conventional methods.
Solution Approach 2:
The patent changes the overlap parameter from multiple meshes (conventional five meshes) to a minimal overlap of one or more single meshes. This parameter change reduces the thickness and discomfort of the junction while maintaining the connection function, directly addressing the comfort issue.
3Ease of manufacture
If planed knitting is used to connect tubular elements, then the connection is achieved, but the article cannot be manufactured in small sizes (e.g., children's gloves) with limited circumference
Solution Approach 1:
The invention introduces dynamics by allowing the knitting machine needle beds to move relative to each other during the connection process. This dynamic adjustment enables the same knitting process to accommodate different sizes (from children's to adult gloves) by adjusting bed positions and stitch transfers, whereas planed knitting is static and size-limited.
Solution Approach 2:
The knitting connection method becomes universal, applicable to tubular elements of any size and circumference. The process of transferring stitches between front and rear beds and connecting through minimal overlap works equally well for small children's gloves and large adult gloves, eliminating the size limitation imposed by planed knitting.
4Manufacturing precision
If fine gauge knitting (number of columns of stitches per cm greater than or equal to 8) is used for tubular elements, then the compressive precision is improved, but the connection between tubular elements becomes difficult to achieve
Solution Approach 1:
The invention uses the knitting machine's needle bed transfer mechanism as an intermediary to connect fine gauge tubular elements. Instead of trying to directly connect fine mesh tubes (which is difficult), the patent uses stitch transfer between beds as an intermediate step, making the connection of fine gauge elements feasible while preserving their precision.
Data Source
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AI summary
One subject of the present invention is an item with a compressive effect (1) comprising a fully knitted component (3) comprising at least a first knitted tubular element (4) and a second knitted tubular element (5), each one having an upper end (4a, 5a) and an open lower end (4b, 5b), the first tubular element (4) being joined to the second tubular element (5) at their lower ends (4b, 5b). Advantageously, the said at least first (4) and second (5) tubular elements each comprise a number of wales of stitches and, possibly of rows of stitches, per centimetre, that is greater than or equal to 8. Another subject of the invention is a method of manufacturing the said item with a compressive effect (1).