Knitted Fabric Compression Zones via Stitch Pattern Variation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional elastic garments require numerous manufacturing operations, leading to uncomfortable protrusions, heat issues, and potential injuries from stitches, while existing methods fail to modulate compression effectively on specific body areas during physical activity.
Innovation Solution
A pocket fabric with elastic warp and weft threads, comprising multiple layers with different elasticities achieved through various weaves, such as plain, twill, and satin, and a method of weaving these threads to create areas with distinct elastic properties, allowing for customizable compression and seamless integration of layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional elastic garments are manufactured using multiple separate pieces assembled by stitching, then the garment can be produced with standard manufacturing processes, but the stitches cause discomfort, heat issues, and potential injuries to the wearer
Solution Approach 1:
The patent merges multiple separate fabric pieces into a single continuous knitted fabric structure. Different elastic zones are created within the same knitted garment by varying the knit stitch patterns in different regions, eliminating the need for stitching multiple pieces together. This resolves the contradiction by maintaining ease of manufacture through single-garment knitting while eliminating harmful stitches entirely.
Solution Approach 2:
The invention extracts and removes the stitching process from the garment manufacturing. By creating all elastic zones and design elements within a single knitted fabric piece, the harmful stitching operation is completely eliminated, preventing discomfort and injury while still allowing complex garment designs to be produced.
2Ease of manufacture
If compression garments use uniform fabric throughout, then the manufacturing process is simple, but the garment cannot provide differentiated compression on specific body areas requiring different elasticities
Solution Approach 1:
The patent applies local quality by varying the knit stitch patterns in different regions of the same garment. Specific zones use tighter knit patterns for higher compression, while other areas use looser patterns for lower compression. This allows the garment to provide differentiated compression on specific body areas while still being manufactured as a single piece, resolving the contradiction between manufacturing simplicity and adaptability.
Solution Approach 2:
The invention incorporates dynamic properties by creating zones with different elasticities within the same knitted fabric. The varying knit densities and stitch patterns allow different parts of the garment to respond differently to body movement and pressure, enabling adaptive compression that adjusts to specific anatomical requirements while maintaining a unified manufacturing process.
3Reliability
If multiple fabric pieces with different elasticities are assembled to create compression zones, then the desired compression effect is achieved, but the garment requires numerous manufacturing operations and assembly steps
Solution Approach 1:
The patent combines multiple fabric pieces with different elasticities into a single continuously knitted garment. The knitting machine produces one unified piece with varying knit patterns that create different elastic zones, eliminating the need for separate manufacturing operations and assembly steps. This resolves the contradiction by maintaining reliable compression effects while dramatically reducing manufacturing complexity.
Solution Approach 2:
The invention applies segmentation at the stitch pattern level rather than at the fabric piece level. Different knit stitch patterns are programmed into specific zones of the single knitted garment to create the required elastic variations, achieving the functional segmentation of different compression zones without the physical segmentation of multiple fabric pieces, thus reducing manufacturing operations.
4Ease of manufacture
If fabric is woven in two dimensions on a linear loom, then the manufacturing process is conventional and simple, but the fabric lacks the three-dimensional structure needed for effective compression garments
Solution Approach 1:
The patent transitions from traditional two-dimensional woven fabric to three-dimensional knitted fabric structure. The knitting process creates inherent depth and volume through interlocking loops, allowing the fabric to conform to and compress three-dimensional body contours more effectively. This resolves the contradiction by maintaining conventional ease of manufacture through standard knitting machines while achieving the required three-dimensional structure.
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
The fabric provides improved comfort and effective modulation of transverse and longitudinal compression, reducing fatigue and enhancing blood circulation without the drawbacks of traditional stitching, making it suitable for sports and medical applications.
Implementation Method 1
a pocket fabric comprising elastic warp threads and elastic weft threads
Implementation Method 2
one of and/or the at least two layers of fabric comprising a plurality of weaves with different elasticities, the weaves defining areas with different elasticities
Data Source
AI summary
A pocket fabric and a method for producing such a fabric, include elastic warp threads and elastic weft threads, and include one or more pockets having at least two stacked layers of fabric in which the warp threads result from the division of the warp threads of a single warp. The at least two layers of fabric are connected to one another by one or more woven joining areas in which the warp thread or threads result from joining the layers of fabric into a single warp, one or more of the at least two layers of fabric including a plurality of weaves with different elasticities, the weaves defining areas having different elasticities in the woven pocket fabric. A garment made of the fabric or including the fabric is also disclosed.