Knitted Window Openings Using Releasable Thermoplastic Yarn
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Solution Overview
Problem
Conventional knitting techniques limit the size, configuration, and shape of apertures in knitted components, requiring inefficient start-and-stop processes and restricting structural and aesthetic design options.
Innovation Solution
A method using a thermoplastic yarn with a lower melting temperature and a non-releasable yarn with a higher melting temperature, where the thermoplastic yarn is heated to create openings while maintaining the integrity of the knitted component, allowing for varied and precise aperture sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If direct knitting technique is used to create openings, then openings can be formed in the knitted component, but the size, configuration and shape of openings are limited
Solution Approach 1:
The yarn is segmented into two distinct components: a releasable yarn (thermoplastic material) and a non-releasable yarn (higher melting point material). This segmentation allows the releasable yarn to be selectively removed to create openings of various sizes and shapes, while the non-releasable yarn maintains the structural integrity of the knitted component, thereby achieving both design versatility and dimensional control
Solution Approach 2:
The invention utilizes parameter changes by heating the knitted component to a temperature that exceeds the melting point of the releasable yarn but remains below the melting point of the non-releasable yarn. This selective thermal parameter change enables precise control over which yarn is removed, allowing creation of openings with controlled dimensions and shapes while maintaining overall structural precision
2Adaptability or versatility
If intarsia hold knitting technique is used to create openings, then openings can be formed, but the knitting process requires starting and stopping at various points
Solution Approach 1:
The releasable yarn is pre-integrated into the knitted component during the knitting process itself, rather than being added or removed later. This preliminary incorporation allows the opening creation to occur through a subsequent heating step rather than requiring repeated start-stop knitting operations, thereby maintaining design versatility while significantly improving production efficiency
Solution Approach 2:
The invention replaces the mechanical start-stop yarn feeder system with a thermal field approach. Instead of mechanically controlling yarn delivery to create openings, a heating system is applied to selectively remove the releasable yarn, substituting a continuous thermal process for an intermittent mechanical process and thereby improving productivity
3Adaptability or versatility
If releasable yarn is heated to create openings, then customizable openings of varying sizes and shapes can be created, but the integrity of the knitted component must be maintained
Solution Approach 1:
The knitted component exhibits local quality differentiation through the use of two yarn types with different thermal properties. The releasable yarn in opening regions has a lower melting point for easy removal, while the non-releasable yarn in structural regions maintains a higher melting point to preserve integrity. This localized material property variation enables customizable openings without compromising overall structural reliability
Solution Approach 2:
The invention employs a composite yarn system combining releasable and non-releasable materials with complementary properties. The releasable thermoplastic yarn provides ease of removal for opening creation, while the non-releasable yarn provides structural strength and thermal stability. This composite approach allows simultaneous achievement of opening customizability and component integrity
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
Enables the creation of knitted components with customizable openings of varying sizes and shapes, enhancing structural and aesthetic properties while maintaining the component's integrity.
Implementation Method 1
a first yarn (110) comprising a thermoplastic material... heating the knitted component (100) to a temperature that exceeds a melting temperature of the first yarn (110)
Data Source
AI summary
A knitted component includes a first yarn and a second yarn, where the first yarn comprises a thermoplastic material having a melting temperature. The first yarn is used to create window openings of different shapes and sizes within the knitted component. This is achieved by using the first yarn to releasably secure adjacent edges of a window opening. The first yarn is then heated to release, at least in part, the first yarn from the edges of the window opening, allowing the edges to separate and thereby form a window opening.