Seamless Circular Knit Fabric With Integrated Cushioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional elastic materials used in shoulder straps, ear loops, and underbands of garments are uncomfortable due to hard edge binding materials that dig into the skin, causing irritation and marks.

Innovation Solution

A seamless circular knit fabric with a continuous circular knit pattern and a cured cushion filling, such as thermoplastic or thermosetting polymer, integrated during the knitting process to provide comfort and softness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional elastic material with edge binding is used for shoulder straps, then the structure is simple and easy to manufacture, but the edge binding material is hard and digs into the skin causing discomfort

Engineering Contradiction:

Improveease of manufactureVSAvoidskin irritation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state of the cushioning material from solid (pre-formed inserts) to liquid/soft state (injectable material) that can be injected into the tubular fabric and then cured. This parameter change allows the material to flow into the fabric structure and bond internally, creating soft contact surfaces that eliminate skin irritation while maintaining manufacturing simplicity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by injecting cushioning material into the tubular knit fabric and curing it in place. The resulting composite combines the elastic properties of the knit fabric with the cushioning properties of the injected material, producing a strap that is both comfortable against skin and easy to manufacture as a single integrated component

Inventive Principle:

Principle #40Composite materials

2Reliability

If pre-cured cushion filling is injected during knitting, then the fabric provides robust and consistent comfort throughout its length, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveconsistent comfortVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the cushioning function with the structural fabric by injecting and curing material directly inside the tubular knit during or after the knitting process. This merging creates a single integrated component where the cushioning filling becomes an integral part of the fabric structure, ensuring consistent comfort throughout the entire length without requiring separate assembly steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs the cushioning function in advance by injecting and curing the cushioning material during or immediately after the knitting process, before the fabric is cut to final length. This preliminary action ensures that the cushioning properties are established throughout the entire continuous fabric length, providing reliable and consistent comfort in every final product segment

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If continuous circular knit fabric is produced without joints, then the fabric provides seamless comfort, but the fabric must be manufactured in a specific continuous manner that limits production flexibility

Engineering Contradiction:

Improveskin irritation from jointsVSAvoidproduction flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent maintains continuous circular knitting without breaking the knit cycle or creating joints, allowing the cushioning material to be injected and cured along the entire continuous length of fabric. This continuity eliminates joints that would cause skin irritation while the ability to cut the continuous fabric to any length afterward provides production flexibility for different product requirements

Inventive Principle:

Principle #20Continuity of useful action

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 seamless fabric offers consistent comfort and softness without joints, reducing skin irritation and providing robust cushioning throughout the length.

Implementation Method 1

a curable cushion filling is injected into the circular knit fabric in a pre-cured state, as the fabric is being knitted. The cushion filling is then cured during the knitting process

Methodology Applied

Scientific EffectCuring:

Implementation Method 2

allows it to flow into and fill the hollow cavity of the circular knit fabric as it is being made

Methodology Applied

Scientific EffectFlow:

Data Source

PatentUS20250283258A1Seamless circular knit fabric, a method of making same and a forming machine using this method, as well as articles comprising straps or bands made therefrom

Publication Date: 2025.09.11 STRETCHLINE INTPROP LTD

AI summary

A seamless circular knit fabric (10) comprising an elastic yarn is provided. The fabric (10) has a continuous circular knit through the length thereof. The circular knit fabric (10) further includes a cured cushion filling (12) inside the circular knit fabric (10) and bonded thereto. The method of making same comprises knitting a yarn to produce a continuous length of circular knit fabric (10), and injecting a curable cushion filling in a pre-cured state inside the circular knit fabric (10). This method uses a circular knit fabric forming machine assembly comprising a circular knitting machine and an injector.