Manufacturing method for knitted fabric having heat generating function
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Solution Overview
Problem
Existing heat-generating textile products often expose electrically conductive yarns, leading to skin burns and discomfort, and rely on specialized batteries, reducing user convenience.
Innovation Solution
A knitted fabric with a four-layer structure where the electrically conductive layer is hidden beneath non-conductive layers, forming protrusions that generate heat when energized, and a three-port USB connector for power supply with adjustable duty cycle, allowing for comfortable use with general-purpose batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrically conductive yarn is used for heat generation, then heat generation function is achieved, but the conductive yarn is exposed on the fabric surface causing skin burns and discomfort
Solution Approach 1:
The conductive yarn is nested within multiple fabric layers (first, second, third, and fourth layers) rather than being exposed on the surface. The first and third layers wrap around the conductive second layer, creating a protective structure that prevents skin contact while maintaining heat generation functionality
Solution Approach 2:
The invention transitions from a single-layer conductive fabric to a multi-layer three-dimensional structure. By distributing conductive yarns across different layers (second, third, and fourth layers) and wrapping them with non-conductive layers, the heat generation function is maintained while the harmful exposure is eliminated through spatial dimensionality
2Temperature
If specialized batteries are used for heat-generating textile products, then heat generation function is achieved, but user convenience and comfort are reduced
Solution Approach 1:
The fabric is designed to be compatible with general-purpose batteries rather than requiring specialized battery systems. The multi-layer structure with distributed conductive yarns can accommodate standard battery configurations, making the heat-generating textile product universally compatible with common power sources and improving user convenience
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 fabric provides a safe and comfortable heat-generating zone without exposing conductive yarns and allows for flexible temperature control using general-purpose batteries, enhancing user convenience and safety.
Implementation Method 1
the second fabric layer is electrically conductive such that when the second fabric layer is electrically energized, air trapped inside the protrusions is heated up, causing the knitted fabric to generate heat
Data Source
AI summary
A knitted fabric having a heat generating function has a four-layer structure and can be knitted by a flat knitting machine. Knit stitching is used to knit first and second layers such that the second layer is fully covered under the first layer. Tuck stitching is used to knit the third layer such that one stitch is made to the third layer per a preset number of stitches made to each of first and second layers. Knit stitching is used to knit the fourth layer. After knitting, the fabric is soaked with water and spin-dried to form protrusions, spatially distributed as a centered rectangular lattice, on fabric surface. The second layer is electrically conductive for generating heat and is hidden inside the fabric. This layer is not easily hooked by a user during use and cleaning. The fabric is elastic and soft, and provides a comfortable feeling to the user.