Plush Knitted Structure With Dual Loop Heights for Climate Comfort
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Solution Overview
Problem
Existing knitted articles with plush zones lack optimal damping and thermal properties due to the use of uniformly thick plush threads, limiting their ability to provide comfortable and effective cushioning and moisture management.
Innovation Solution
The use of two distinct plush threads with different heights and materials, forming multiple layers or planes within the knitted fabric, where longer plush loops from natural fibers like wool provide enhanced cushioning and heat retention, while shorter loops from man-made fibers like PA facilitate moisture dissipation, creating a triple-layer construction for improved comfort and climatic management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniformly thick plush threads are used in knitted articles, then the structure is simple and manufacturing is easy, but the damping and cushioning properties are insufficient
Solution Approach 1:
The patent applies local quality by using plush threads of different thicknesses (first plush thread and second plush thread) in different regions of the knitted article. The first plush thread with lower yarn count (thicker) is used in zones requiring enhanced damping and cushioning, while the second plush thread with higher yarn count (thinner) is used in other areas. This creates localized variations in plush loop heights and densities, optimizing performance for specific functional requirements without complicating the entire structure.
Solution Approach 2:
The patent segments the plush fabric into distinct zones with different plush thread characteristics. The knitted article is divided into multiple plush zones where each zone can be formed from different plush threads with different yarn counts. This segmentation allows independent optimization of damping, cushioning, and moisture management properties in different regions, resolving the contradiction between performance and structural simplicity.
2Strength
If thicker plush threads are used to improve damping and cushioning, then the supporting effect is enhanced, but the moisture management capability is reduced
Solution Approach 1:
The patent resolves this contradiction by applying local quality through spatial differentiation of plush thread types. Thicker plush threads (first plush thread) are strategically placed in zones where damping and cushioning are prioritized, while thinner plush threads (second plush thread) are used in zones where moisture management is more critical. This localized approach allows the article to provide enhanced supporting effect in specific areas without compromising overall moisture management capability.
3Adaptability or versatility
If separate plush zones with different plush threads are knitted, then optimal damping and moisture management are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the knitted article into multiple plush zones that can be formed from different plush threads. Each zone is independently optimized for specific functions (damping, cushioning, moisture management) while maintaining compatibility with standard knitting processes. This segmentation enables functional optimization without requiring entirely new manufacturing approaches, as each zone can be produced using conventional knitting techniques with appropriate thread selection.
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 configuration enhances the knitted article's cushioning, thermal, and moisture management properties, offering a more pleasant wearing experience with optimized climatic control and reduced sweating, by leveraging the unique properties of different fibers and loop lengths.
Implementation Method 1
the first and the second plush loops have dissimilar heights... the longer plush loops which project the furthest from the plane of the basic knitted fabric and also protrude beyond the first plane of plush loops... pleasant haptic perception or a pleasant wearing comfort
Implementation Method 2
the dissipation of moisture from the knitted article by virtue of the capillary effect and due to the fact that the plush loops are routed through the right knitwear side
Data Source
AI summary
A knitted article, having a basic knitted fabric which is knitted from at least one basic knitted fabric thread, and at least two plush threads which are plated on the basic knitted fabric thread and which configure first and second plush loops, wherein the first and the second plush loops have dissimilar heights.