Double-Layer Knitted Fabric Moisture Transfer via Stitch Segmentation

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Solution Overview

Problem

Existing double-layer knitted fabrics with a hydrophobic inner layer and hydrophilic outer layer often cause discomfort due to retained moisture close to the skin, as hydrophilic stitches within the inner layer can touch the wearer and only the feet of stitches effectively transport moisture away.

Innovation Solution

A method of manufacturing a double-layer knitted fabric where hydrophilic yarn stitches are formed on both needle beds, then transferred and split on the second needle bed, allowing only the legs and feet of these stitches to be part of the inner layer, reducing moisture retention and enhancing moisture transfer to the outer layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydrophilic yarn is knitted on selected needles of the second needle bed to form inner layer stitches, then moisture can be transported from skin to outer layer, but the hydrophilic stitches touch the skin and retain moisture close to the skin causing discomfort

Engineering Contradiction:

Improvemoisture transport capabilityVSAvoidmoisture retention near skin

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The stitch structure is segmented into two distinct parts: the foot of the stitch remains on the second needle bed and forms the inner layer touching the skin, while the head of the stitch is transferred to the first needle bed and forms the outer layer. This segmentation allows the hydrophilic yarn to transport moisture effectively while minimizing skin contact area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention utilizes the dimensional aspect of stitch structure by separating the foot and head of the stitch into different layers (inner and outer). The foot remains in the inner layer dimension while the head moves to the outer layer dimension through transfer, creating a three-dimensional stitch configuration that optimizes both moisture transport and comfort.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If hydrophilic yarn is knitted on all needles of the first needle bed to form outer layer, then moisture storage capability is improved, but the outer layer may still touch the skin and cause discomfort

Engineering Contradiction:

Improvemoisture storage capacityVSAvoidskin contact with hydrophilic material

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The harmful effect of hydrophilic yarn touching the skin is extracted by transferring only the head of the stitch to the outer layer, while the foot remains in the inner layer. This extraction ensures that the moisture storage function is maintained in the outer layer while the skin contact function is restricted to the hydrophobic inner layer only.

Inventive Principle:

Principle #2Taking out (Extraction)

3Device complexity

If only the feet of stitches transport moisture into the second layer, then the inner layer structure is simple, but most moisture is still retained close to the skin

Engineering Contradiction:

Improveinner layer stitch structureVSAvoidmoisture transport efficiency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The head of the stitch is prepared on the second needle bed and then transferred to the first needle bed before the knitting cycle completes. This preliminary transfer action ensures that the hydrophilic yarn is positioned in the outer layer before the stitch is fully formed, maximizing moisture transport efficiency while maintaining structural simplicity.

Inventive Principle:

Principle #10Preliminary action

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

This approach significantly improves moisture transfer and comfort by minimizing moisture retention near the skin, allowing both legs and feet of the stitches to move moisture away, making the wearer feel dry and comfortable.

Implementation Method 1

By a capillary effect the inner layer is moving moisture from the skin to the outer layer.

Methodology Applied

Scientific EffectCapillary effect: Capillary Action

Implementation Method 2

an outer layer made of a hydrophilic yarn... that is able to store moisture

Methodology Applied

Scientific EffectHydrophilic absorption: Absorption (physical)

Data Source

PatentUS11959205B2Method to produce a double-layer knitted fabric

Publication Date: 2024.04.16 ESSITY HYGIENE & HEALTH AB

AI summary

A method of manufacturing a double-layer knitted fabric such as a compression article is provided. The method is performed on a knitting machine having at least two needle beds. The knitted fabric includes an outer layer made of a hydrophilic yarn on the first needle bed and an inner layer made of a hydrophobic yarn on the second needle bed. The method includesa. Forming of stitches with a hydrophilic yarn with all needles of the first needle bed and with selected needles of the second needle bed;b. transferring the stitches made of the hydrophilic yarn and formed on the selected needles of the second needle bed to needles of the first needle bed;c. immediately after transferring the stitches, forming of stitches with a hydrophobic yarn on the selected needles of the second needle bed as well as with all other needles of the second needle bed.