Knitted Fabric Dimensional Stability via Elastic Yarn Loop Structure
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Solution Overview
Problem
Existing knitted fabrics face challenges in achieving dimensional stability and elasticity while maintaining a woven appearance, often requiring complex processes and higher production costs, which can affect wearing comfort and fabric integrity.
Innovation Solution
A single-sided knitted fabric is developed using a combination of elastic yarn and polyurethane fiber, where the yarns are fed and formed into loops to create a dense, elastic structure that mimics woven fabric appearance and provides improved dimensional stability without requiring special processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If bonding fiber is used to improve dimensional stability through heat setting, then dimensional stability is improved, but production cost increases and process complexity increases
Solution Approach 1:
The patent extracts and eliminates the bonding fiber component from the fabric structure. Instead of using bonding fiber with heat setting to achieve dimensional stability, the invention uses a double-sided knit structure where the inherent loop structure and interlocking of yarns on both sides provide stability without requiring additional bonding agents or complex heat setting processes.
Solution Approach 2:
The double-sided knit structure serves multiple functions simultaneously: it provides dimensional stability, maintains fabric integrity, eliminates the need for bonding fiber, and avoids complex heat setting processes. The same structural design achieves both aesthetic appearance and functional performance without requiring separate components or processes.
2Stability of the object's composition
If bonding fiber is used to improve dimensional stability, then dimensional stability is improved, but production cost increases
Solution Approach 1:
The patent removes the bonding fiber component entirely from the manufacturing process. The dimensional stability is achieved through the double-sided knit structure itself, eliminating the need to purchase, handle, and process bonding fiber, thereby reducing production costs while maintaining fabric stability.
3Volume of stationary object
If high shrinkage polyester filament yarn is used to improve density, then density is improved, but extensibility deteriorates and wearing comfort is affected
Solution Approach 1:
The patent employs a dynamic double-sided knit structure where the loops and coils on both sides of the fabric can move and adjust relative to each other. This dynamic structure allows the fabric to maintain high density through the interlocking loops while simultaneously providing extensibility as the loops can deform and shift under stress, ensuring both density and wearing comfort.
4Stability of the object's composition
If warp-knitted structure with polyurethane elastic fiber is used to improve dimensional stability, then dimensional stability is improved, but process complexity increases and cost increases
Solution Approach 1:
Instead of using a traditional warp-knitted structure that requires complex machinery and multiple yarn feeds to achieve dimensional stability, the patent inverts the approach by using a double-sided knit structure where the stability emerges naturally from the interlocking loops on both sides. This simplifies the knitting process while achieving the same or better dimensional stability.
Data Source
AI summary
A knitted fabric and a use thereof are described, where the knitted fabric is a single-sided knitted fabric including an elastic yarn A and a polyurethane fiber, and a coil surface that includes a coil together formed by the elastic yarn A and the polyurethane fiber that are separately fed, and where the knitted fabric is close to a woven fabric in appearance and performance, has good elasticity, and is particularly suitable for manufacturing coats, trousers, dresses or the like.