Seamless Garment Structure Using Circular Knitting
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Solution Overview
Problem
Current garments, especially sports wear and underwear, face challenges in providing unrestricted movement and comfort due to stitching, which causes discomfort, restricts movement, and is aesthetically unacceptable, while also increasing production costs and reducing versatility.
Innovation Solution
A seamless garment structure with a single stitching line that integrates tubular elements for the torso and sleeves, using circular knitting to create a flexible, elastic fabric that eliminates stitching constraints, allowing for calibrated tension and seamless graphic designs, promoting optimal movement and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stitching is used to join garment parts, then structural integrity is achieved, but movement freedom and comfort are reduced
Solution Approach 1:
The patent merges the torso and sleeves into a single seamless knitted structure, eliminating the need for stitching to join separate parts. This integration maintains structural integrity while removing stitching-induced constraints on movement freedom.
Solution Approach 2:
The invention extracts and removes stitching elements from the garment construction process. By using circular knitting to create a seamless structure, the harmful stitching component is completely eliminated from critical movement zones, resolving the contradiction between structural integrity and movement freedom.
2Strength
If stitching is used to join garment parts, then structural integrity is achieved, but comfort and skin contact quality deteriorate
Solution Approach 1:
The invention extracts and removes stitching elements from the garment construction. By using seamless circular knitting, the harmful stitching component that causes discomfort and skin irritation is completely eliminated, while structural integrity is maintained through the continuous knitted fabric structure.
Solution Approach 2:
The patent applies different knitting patterns and yarn compositions in different zones of the garment to optimize local properties. This allows the fabric to provide appropriate support and comfort in specific areas without requiring stitching, maintaining both structural integrity and skin contact quality.
3Productivity
If stitching is reduced in garments, then production costs and processing time are reduced, but garment durability may be affected
Solution Approach 1:
The patent merges multiple garment parts into a single seamless knitted structure produced in one continuous process. This eliminates multiple stitching operations, reducing production time and costs while actually improving durability by removing weak points where stitching creates stress concentration.
Solution Approach 2:
The invention extracts stitching operations from the production process entirely. By using seamless circular knitting, the garment is produced in one continuous process without stitching steps, reducing processing time and costs while eliminating the durability issues associated with stitched joints.
4Ease of operation
If seamless structure is used, then movement freedom and comfort are improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses circular knitting machines that automatically create seamless structures through self-contained cyclic processes. The machine performs all necessary operations (knitting, shaping, finishing) in one continuous automated sequence, eliminating the need for complex assembly operations and reducing overall manufacturing complexity despite the advanced seamless structure.
Solution Approach 2:
The invention uses multi-functional circular knitting machines capable of producing different garment parts and patterns in a single process. This universal equipment handles multiple operations that would traditionally require separate machines and steps, reducing manufacturing complexity while enabling seamless construction.
Data Source
AI summary
A garment structure for making a base layer or midlayer jersey for sporting activities that includes a first tubular element that corresponds to both the front and the rear zone of the torso and a second tubular element that affects arms, shoulders and part of the torso in which both the first element and the second are obtained with circular machines making a knitted fabric that provides different processing that enable functional and structural features to be given to the knitted fabric and to the garment. In particular, the first tubular element has a cylindrical conformation with a lower edge that bounds the length of the jersey and an upper end divided into a pair of profiles: a first profile defined, laterally, by the line of the sides and a second profile that leads away from the line of the sides continuing the first profile with a trapezium configuration.