Knitted Polyester-Spandex Throw Structure for Soft Thermal Insulation
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Solution Overview
Problem
Conventional methods for producing throws result in limited design options, higher production costs, and environmental concerns due to water, energy, and chemical usage, with varying quality and insulating performance.
Innovation Solution
A method involving knitting an outer fabric with 90%-95% Drawn Texturized Yarn (DTY)/Fully Drawn Yarn (FDY) polyester and 5%-10% spandex, and an inner filling of 100% three-dimensional (3D) poly fill polyester, using a Karl Mayer® warp knitting machine, with dyeing and bleaching procedures to create a squishy and soft throw.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional knitting and processing methods are used to produce throws, then the throws can be manufactured with standard quality, but the production costs increase and design options are limited
Solution Approach 1:
The patent changes the material parameters by using 90%-95% Drawn Texturized Yarn (DTY)/Fully Drawn Yarn (FDY) polyester combined with 5%-10% spandex, and 100% three-dimensional (3D) poly fill polyester for the inner filling. This parameter change enables unique soft and squishy texture while maintaining manufacturing efficiency, resolving the contradiction between design options and production costs
Solution Approach 2:
The patent employs composite materials by combining polyester and spandex in the outer fabric and using 3D poly fill polyester for the inner filling. This composite approach creates a throw with enhanced softness, squishiness, and insulating performance, providing design flexibility while controlling production costs through optimized material composition
2Reliability
If conventional knitting and processing methods are used to produce throws, then the throws can be manufactured with standard quality, but environmental sustainability deteriorates due to extensive water, energy, and chemical usage
Solution Approach 1:
The patent changes the material composition parameters to use 90%-95% Drawn Texturized Yarn (DTY)/Fully Drawn Yarn (FDY) polyester and 5%-10% spandex, reducing the need for extensive water, energy, and chemical processing while maintaining standard quality. This parameter change improves environmental sustainability by minimizing harmful factors in the manufacturing process
Solution Approach 2:
The patent employs 100% three-dimensional (3D) poly fill polyester for the inner filling, which provides excellent insulating performance and softness while being cost-effective and environmentally friendly. This material choice reduces the need for complex processing and minimizes environmental impact, aligning with sustainable manufacturing principles
3Reliability
If conventional methods are used to produce throws, then the manufacturing process is established, but the quality and insulating performance vary depending on manufacturing process and materials
Solution Approach 1:
The patent specifies precise parameter changes: 90%-95% Drawn Texturized Yarn (DTY)/Fully Drawn Yarn (FDY) polyester with 5%-10% spandex for the outer fabric, and 100% three-dimensional (3D) poly fill polyester for the inner filling with GSM ranges of 200-300 for outer fabric and 100-180 for inner filling. These controlled parameter changes ensure consistent quality and insulating performance while simplifying the manufacturing process
Solution Approach 2:
The patent applies local quality by using different material compositions for the outer fabric and inner filling. The outer fabric uses 90%-95% DTY/FDY polyester with 5%-10% spandex for durability and stretch, while the inner filling uses 100% 3D poly fill polyester for softness and insulation. This localized material optimization ensures high quality and insulating performance throughout the throw while maintaining a relatively simple manufacturing process
Data Source
AI summary
A method comprising one or more polyester and spandex materials from external sources. A specificity of the polyester and spandex materials is identified before obtaining the one or more polyester and spandex materials. The method also comprises combining the one or more polyester and spandex materials in one or more knitting processes to create an outer fabric. The method also includes obtaining surface yarns and spandex yarn. A specificity of the surface yarns and spandex yarn is also obtained. The method also includes combining the surface yarns and spandex yarn into an inner filling. Further the method includes placing the inner filling into the outer fabric.