One-Piece Lower-Body Knitting for Seamless Gusset Fit
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Solution Overview
Problem
Existing knitted articles for the lower body are often constructed in multiple pieces, leading to waste and discomfort due to seams, particularly in the gusset area, and limit structural possibilities to single jersey or purl, lacking essential features like ribs for performance and fit.
Innovation Solution
A method using a flatbed knitting machine to create a one-piece knitted article with three interconnected portions and seams facing away from each other, allowing for non-planar shaping, multiple structures, and seamless gussets, while enabling compression properties and incorporating features like pockets without seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pieces are used to construct knitted articles, then manufacturing flexibility and structural variety are improved, but material waste increases and production time increases
Solution Approach 1:
The patent combines multiple knitted pieces into a single continuous knitted article that covers the lower body from waist to ankles. This one-piece construction eliminates the need to join separate components, thereby reducing material waste from cutting and joining operations while maintaining the ability to incorporate various structures like ribs, pockets, and gussets through the knitting process itself.
2Strength
If seams are present in the gusset area, then structural integrity is improved, but wearer comfort deteriorates due to skin irritation
Solution Approach 1:
The patent removes seams from the gusset area by incorporating the crotch and leg openings directly into the continuous knitted structure. The gusset is formed as an integral part of the one-piece construction without requiring separate pieces to be joined, thereby eliminating the source of skin irritation while maintaining structural integrity through the knitting pattern itself.
3Strength
If seams are present in the gusset area, then structural integrity is improved, but fabric stretching performance deteriorates due to restricted or uneven stretching
Solution Approach 1:
The patent merges the gusset construction with the surrounding fabric into a continuous knitted structure. This seamless integration allows the fabric to stretch uniformly in all directions without being constrained by seam lines, enabling the material to conform naturally to body movements while maintaining overall structural integrity through the knitting pattern.
4Object-affected harmful factors
If tubular technique on flatbed machine is used, then seamless construction is improved, but structural possibilities are limited to single jersey or purl
Solution Approach 1:
The patent employs a flatbed knitting machine capable of performing multiple knitting techniques including ribs, purl, and combination structures within a single continuous production process. This multi-functional approach allows the machine to create various fabric structures and design features without requiring separate production steps or limiting the seamless one-piece construction, thereby achieving both seamless benefits and structural versatility.
Data Source
AI summary
A method for generating a knitted article having a first, second and third opening, the knitted article adapted to cover at least a groin, a first thigh portion and a second thigh portion of a human body. The method includes using flatbed knitting machine to knit a first portion of the knitted article for covering the first thigh portion, then to knit a second portion of the knitted article for covering the groin and then to knit a third portion of the knitted article for covering the second thigh portion. The first, second and third portions of the knitted article form a one-piece, non-planar knitted article. A pair of edges of the knitted article are affixed to form a first seam, and another pair of edges are affixed to form a second seam facing away from the first seam.