Seamless Knitted Garment Pouch Structure for Chafing Reduction
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Solution Overview
Problem
Traditional male garments like boxers and jockstraps often feature unsightly and uncomfortable seams at the groin region due to cut and sew constructions, leading to discomfort and potential chafing during wear.
Innovation Solution
A seamlessly knitted structure for male garments comprising a main fabric layer, a support fabric layer made of high modulus materials like spandex or thermoplastic polyurethane, and a pouch fabric layer, all knitted together to form a seamless pouch space without seams, using a knitting machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional cut and sew construction is used, then manufacturing is easier and components can be separately formed, but seams and stitches are created at the groin region causing discomfort and chafing
Solution Approach 1:
The patent merges multiple separately formed components (waistband, pouch, straps, leg openings) into a single continuously knitted garment structure. The knitting machine produces the entire garment as one seamless piece, eliminating the need for separate component assembly and the resulting seams at the groin region, thereby improving comfort while maintaining manufacturing efficiency through automated knitting.
Solution Approach 2:
The garment is functionally segmented into distinct regions (waistband region, pouch region, strap regions, leg opening regions) with different knit structures and properties, while being produced as a continuous seamless structure. Each region has optimized characteristics for its specific function, achieving component-level performance without component-level assembly.
2Adaptability or versatility
If separately formed components are joined together, then manufacturing flexibility is improved, but unsightly and uncomfortable joints are created at the groin region
Solution Approach 1:
The invention combines multiple functional components into a single seamless knitted structure, eliminating joints and seams at the groin region that cause discomfort. The continuous knitting process ensures no uncomfortable connections between components while maintaining design flexibility through varied knit patterns and material selection within the unified structure.
3Ease of operation
If seamless knitting is used, then comfort and elimination of seams are improved, but manufacturing process complexity increases
Solution Approach 1:
The invention replaces traditional mechanical cutting and sewing processes with a seamless knitting process. The knitting machine creates the entire garment structure through programmed yarn insertion and loop formation, eliminating the need for separate cutting, stitching, and assembly operations. This substitution reduces overall manufacturing complexity despite the advanced knitting technology required.
4Duration of action of stationary object
If traditional construction with stitches is used, then manufacturing is simpler, but durability is reduced due to seam stress and potential failure points
Solution Approach 1:
The seamless knitting process merges all garment components into a continuous structure without seams or stitches that could fail. The continuous knitted fabric eliminates stress concentration points at seam intersections, significantly improving durability and longevity of the garment while maintaining manufacturing efficiency through automated single-step production.
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 seamless construction reduces chafing and enhances comfort, durability, and breathability, while providing support and customizable features for improved fit and functionality.
Implementation Method 1
seamlessly knitting the knitted structure using a knitting machine
Implementation Method 2
the support fabric layer formed of a stiffer material than the main fabric layer and comprising yarns made of high modulus material, the high modulus material including spandex, elastane
Data Source
Figure 1~2A
Figure 2B~3
Figure 4A~4B
AI summary
The present disclosure generally relates to a seamlessly knitted structure (100) for a male garment (200), the knitted structure (100) comprising: a main fabric layer (110); a support fabric layer (120) knitted to the main fabric layer (110), the support fabric layer (120) formed of a stiffer material than the main fabric layer (110); and a pouch fabric layer (130) knitted to and extending outwardly from the main fabric layer (110) and supported by the support fabric layer (120), the pouch fabric layer (130) forming a pouch space for accommodating a groin region of a male user wearing the male garment (200) comprising the knitted structure (100).