Knitted product and method for producing knitted product
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Knitted products using natural or synthetic fiber yarns face issues with shrinkage and stretching due to washing, and require large-scale heat treatment apparatuses for heat-fusible yarn fusion, which can damage fibers and complicate small lot production.
Innovation Solution
A heat-fusible yarn that melts at 105°C or less is fused with the ground yarn using a flat knitting machine, and then melted with a steam iron to prevent shrinkage and stretching without requiring large-scale equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heat treatment with dry heat at 120°C for 1 minute or wet heat at 110°C for 30 seconds is performed to fuse heat-fusible yarn with ground yarn, then shrinkage and stretching of the knitted product are prevented, but fibers may be damaged compromising the feel of the knitted product
Solution Approach 1:
The patent changes the melting point parameter of the heat-fusible yarn from conventional high melting points (requiring 110-120°C treatment) to a lower melting point of 105°C or less. This parameter change enables effective fusion at lower temperatures, preventing fiber damage while maintaining shape stability of the knitted product.
2Stability of the object's composition
If large-scale heat treatment apparatus such as pin tenter dry heat setting machine or autoclave wet heat setting machine is used to perform heat treatment, then heat-fusible yarn is effectively fused with ground yarn, but capital investment becomes necessary and small lot production becomes difficult
Solution Approach 1:
The patent replaces expensive, large-scale industrial heat treatment apparatus with simple, inexpensive tools such as a steam iron. This substitution enables small lot production and eliminates the need for capital investment in large-scale equipment while still achieving effective fusion of heat-fusible yarn with ground yarn through the lowered melting point of 105°C or less.
3Stability of the object's composition
If conventional heat treatment process is used to fuse heat-fusible yarn, then shrinkage is prevented, but long production period is required due to need for factory having large-scale heat treatment apparatus
Solution Approach 1:
The patent enables simple heat treatment using accessible tools like a steam iron, eliminating the need to transport knitted fabrics to specialized factories with large-scale apparatus. This dramatically reduces the production period and enables rapid processing while maintaining effective fusion and shape stability through the lower melting point heat-fusible yarn.
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 method effectively prevents shrinkage and stretching of natural or synthetic fiber yarns, maintains product feel, and allows for small lot, efficient production suitable for individualized needs.
Implementation Method 1
it is necessary to perform heat treatment with dry heat at 120° C. for 1 minute, or heat treatment with wet heat at 110° C. for 30 seconds in order to cause the heat-fusible yarn to be fused with the ground yarn
Implementation Method 2
a heat-fusible yarn that melts at 105° C. or less is fused with a whole or a part of a ground yarn
Data Source
AI summary
A heat-fusible yarn that melts at 105° C. or less is fused with a whole or a part of a ground yarn that is a natural fiber yarn and/or a synthetic fiber yarn. A knitted product including the heat-fusible yarn in an unmelted state is efficiently produced by form-knitting with use of a flat knitting machine while knitting the heat-fusible yarn into the whole or a part of the ground yarn. The heat-fusible yarn melts at 105° C. or less, thereby causing the heat-fusible yarn to melt and to be fused with the ground yarn by a steam iron without using a large-scale heat treatment apparatus. The heat-fusible yarn is fused with the ground yarn of the knitted product, thereby preventing shrinkage and stretching of the ground yarn.