Continuous Knitted Fabric for Wound Dressings
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Solution Overview
Problem
The manufacturing of spacer layers for wound dressings is challenging due to their stretch properties and poor dimensional stability, leading to difficulties in handling and processing, particularly in continuous roll processes, resulting in high fibre shedding and health hazards associated with batch processing.
Innovation Solution
A method using a knitting machine with a configuration of adjacent needles separated by empty needles to produce a continuous knitted fabric, avoiding batch processing and reducing fibre shedding, allowing for efficient production of wound dressing fabrics with desired widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing is used to manufacture spacer fabric, then the fabric can be produced, but the process is slow, highly labour intensive, and results in high fibre shedding
Solution Approach 1:
The patent implements a continuous knitting process where yarn is continuously fed through the knitting machine to produce spacer fabric without stopping or batch interruptions. This continuous action eliminates the stopping and starting inherent in batch processes, thereby increasing productivity and reducing fibre shedding caused by repeated handling and blade contact.
Solution Approach 2:
The patent extracts and eliminates the cutting operation from the manufacturing process by knitting the fabric to its final required width directly in the continuous process. This removes the source of fibre shedding associated with cutting blades while maintaining the ability to produce fabric of specific dimensions.
2Productivity
If roll to roll processing is used for spacer fabric, then continuous production is possible, but the stretch properties and poor dimensional stability make handling and control difficult
Solution Approach 1:
The patent performs preliminary stabilization by knitting the fabric with controlled tension and structure directly in the continuous process, establishing dimensional stability before the fabric enters the roll-to-roll handling system. This preliminary action prevents excessive stretching and dimensional changes during subsequent handling.
Solution Approach 2:
The patent controls key parameters including yarn tension, knitting stitch pattern, and fabric density to optimize the dimensional stability of the spacer fabric during continuous production. By adjusting these parameters, the fabric maintains adequate stability for roll-to-roll handling while preserving its functional stretch properties.
3Length of moving object
If inline cutting or slitting is performed on spacer fabric, then the fabric can be divided into required sizes, but the poor dimensional stability and stretch properties make the cutting difficult to control
Solution Approach 1:
The patent performs preliminary sizing by knitting the fabric to its final required width directly in the continuous knitting process. This eliminates the need for subsequent cutting operations, thereby avoiding the dimensional control issues associated with cutting stretchable, unstable fabric while still achieving the desired fabric dimensions.
Data Source
AI summary
The disclosed technology relates to methods of manufacturing a fabric (100) for a wound dressing in which a knitting machine (500) is configured to knit a plurality of yarns to form a knitted fabric (100), and a fabric formed according to the method. The disclosed technology also relates to a system, a computer program and a non-transitory computer readable medium.