Engineered Knitted Garment With Seamless Graded Compression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing compression garments have seams that cause chafing, increased fabric waste, and higher manufacturing costs due to the need for cutting and sewing fabrics with different structural properties to achieve varying levels of compression.
Innovation Solution
An engineered knitted garment with integrated compression zones created using a warp knitting machine equipped with two jacquard guide bars, allowing seamless transitions and varying levels of compression by incorporating different amounts of elastane yarn through jacquard patterns, ensuring seamless integration of zones with varying compressive moduli.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If compression garments are made by cutting and sewing fabrics with different structural properties to provide different levels of compression, then varying levels of compression can be achieved, but seams are created that cause chafing
Solution Approach 1:
The patent combines multiple fabric pieces with different structural properties into a single seamless knitted garment. The knitting machine integrates different yarn compositions (e.g., varying elastane content) and knit structures (e.g., different stitch patterns, densities, or textures) within the same garment, eliminating the need for separate fabric pieces and seams while maintaining zone-specific compression properties.
Solution Approach 2:
The patent implements local quality by creating different compression zones within the same knitted garment through spatial variation in yarn composition and knit structure. Specific areas (e.g., calves, thighs, waist) are engineered with different elastane content ratios and knit densities to provide customized compression levels where needed, while the rest of the garment maintains a base structure.
2Adaptability or versatility
If compression garments are made by cutting and sewing fabrics with different structural properties, then different levels of compression can be provided, but fabric waste increases
Solution Approach 1:
The patent merges the production of multiple compression zones into a single continuous knitting process. The knitting machine produces the entire garment or large sections of it in one operation, integrating different fabric properties (varying elastane content, different knit structures) without requiring separate fabric pieces to be cut and assembled, thereby minimizing fabric waste.
Solution Approach 2:
The patent utilizes parameter changes during the knitting process to create different compression zones. By dynamically adjusting yarn feed rates, elastane content ratios, and knit structure parameters (stitch type, density, tension) during production, the garment achieves varying compression levels throughout different body zones without requiring separate fabric pieces, thus reducing material waste.
3Adaptability or versatility
If compression garments are made by cutting and sewing fabrics with different structural properties, then varying compression can be achieved, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single knitting process. Instead of separately producing different fabric pieces with varying properties and then assembling them through cutting and sewing, the knitting machine produces the entire multi-zone compression garment in one continuous operation, reducing labor requirements and manufacturing complexity.
Solution Approach 2:
The patent employs parameter changes during the knitting process to create different compression zones. By adjusting yarn composition (elastane content), knit structure (stitch type, density), and tension parameters dynamically during production, the garment achieves customized compression levels for different body zones without requiring separate manufacturing processes or assembly steps, thereby reducing manufacturing cost.
4Adaptability or versatility
If seams are used to create different compression zones, then varying compression levels can be achieved, but garment comfort decreases due to chafing
Solution Approach 1:
The patent merges different compression zones into a seamless single-piece knitted garment. The knitting machine produces continuous fabric without cuts or seams, integrating zones with different compression properties (achieved through varying yarn composition and knit structure) directly into the garment body, thereby eliminating chafing and improving comfort while maintaining functional compression differentiation.
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 solution provides a seamless, cost-effective, and comfortable garment with graded compression levels, reducing chafing and fabric waste while maintaining high performance and support where needed.
Implementation Method 1
The garment may include a first compression zone, a second compression zone, and a third compression zone with different compressive moduli to provide graded compression levels
Data Source
AI summary
The present disclosure provides for engineered knitted garments multiple compression zones. The compressive moduli of the compression zones may be different to provide higher compression in areas where greater support is required and lower compression in areas requiring less support.