Method for making assembled textile products
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Solution Overview
Problem
Traditional methods for manufacturing assembled textile products, such as jackets and dresses, face limitations in wearability, comfort, elasticity, flexibility in knitting patterns, manufacturing time, and cost-effectiveness, particularly due to the stiffness of fabrics and limitations of traditional knitting machines.
Innovation Solution
A method involving the production of tubular knitted fabric using circular knitting machines, stretching, applying heat adhesive material, and cutting to create open pieces of fabric, which are then assembled into textile products, allowing for high wearability, comfort, and flexibility without the need for elastic yarns, and enabling rapid production of varied designs at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rectilinear knitting machines or large circular knitting machines are used to manufacture fabrics, then the fabrics have high structural stiffness and stability, but the assembled textile products have corresponding stiffness that limits wearability and user comfort
Solution Approach 1:
The patent changes the physical parameters of the knitting process by using circular knitting machines with diameters between 3.5 and 22 inches, which produce fabrics with different structural characteristics compared to traditional rectilinear machines. This parameter change in machine diameter and knitting geometry results in fabrics with reduced stiffness while maintaining adequate stability, thereby improving wearability and user comfort without sacrificing essential fabric integrity.
2Productivity
If traditional knitting machines are used, then fabrics can be manufactured in very long pieces with high production volume, but the flexibility in fabric type, fineness, and knitting patterns is limited
Solution Approach 1:
The patent introduces dynamic adaptability to the knitting process by enabling the circular knitting machines to produce different fabric types, fineness levels, and knitting patterns on demand. The system transitions from static, fixed-pattern production to dynamic, flexible production where the same machine can rapidly switch between different fabric specifications, accommodating diverse product requirements while maintaining efficient production volumes.
3Ease of manufacture
If traditional knitting machines with complex initial setup are used, then large amounts of fabric can be manufactured at low cost, but the manufacturing process has low flexibility for small productions and samples
Solution Approach 1:
The patent segments the production process into flexible modules using circular knitting machines that can produce fabric in optimized quantities rather than requiring large batch production. This segmentation allows manufacturers to produce smaller batches economically, making the manufacturing process adaptable to both small production runs and larger volumes without the need for complex reconfiguration or sacrificing cost efficiency.
4Stability of the object's composition
If traditional knitting machines are used, then fabrics with specific stability properties can be produced, but the manufacturing time is quite long
Solution Approach 1:
The patent replaces the traditional rectilinear knitting mechanism with a circular knitting mechanism, substituting one mechanical system for another that operates more efficiently. The circular motion and needle arrangement in these machines enable faster fabric production while maintaining the required stability properties, thereby reducing manufacturing time without compromising fabric quality or structural 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
This method enhances the wearability and comfort of textile products, offers a wide range of textile effects, reduces manufacturing time and costs, and increases production flexibility, enabling efficient production of small batches with high quality.
Implementation Method 1
applying a heat adhesive material onto at least a first portion of an outer surface of the tubular fabric pulled over the support, and heating the heat adhesive material applied onto the tubular fabric so as to let the heat adhesive material firmly adhere under heat onto the tubular fabric
Data Source
Figure 1A~1D
Figure 2
AI summary
A method for making assembled textile products comprising the following steps: arranging an open piece of fabric, made by producing a tubular knitted fabric (1) by means of a circular knitting machine for hosiery or for knitwear, by pulling the tubular fabric (1) over a support (2) so as to stretch the tubular fabric (1), by applying a heat adhesive material (4) onto at least a first portion of an outer surface of the tubular fabric (1) pulled over the support (2) letting the heat adhesive material (4) firmly adhere under heat onto the tubular fabric (1), and by cutting the tubular fabric (1) onto which the heat adhesive material (4) has been applied, so as to obtain an open piece (9) of fabric; cutting the open piece of fabric according to predefined cutting lines for making one or more parts of a textile product to be assembled, and assembling a plurality of parts obtained from the open piece (9) of fabric or from a plurality of pieces of fabric for obtaining an assembled textile product, in particular a jacket, a pair of trousers, a men's suit, a women's dress.