Single layered garment fabric
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Solution Overview
Problem
Modern engineered textiles, such as those used in garments, face challenges in harmoniously combining multiple functional attributes like stability, support, and compression due to complex assembly techniques and contrasting nature of attributes, making it difficult to produce high-performance textiles that balance these requirements in a single layer.
Innovation Solution
A method of manufacturing a single layer garment using low melt yarn with selective heating, where the textile material is formed using either a molding machine or a hot air machine, allowing for customized support and moisture management by creating three-dimensional profiles and selectively heating specific areas to provide support and lock in zones for stability and stretch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple functional attributes (stability, support, compression) are combined in traditional multi-layer garments, then functional performance is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple functional attributes (stability, support, compression, moisture management) into a single layered fabric structure. The engineered knit fabric integrates different yarn types (elastane for compression, polyester for stability, spandex for stretch) within one layer, eliminating the need for multiple separate layers and complex assembly processes while maintaining all required functional performances.
Solution Approach 2:
The single layered fabric is designed to perform multiple functions simultaneously: providing compression through elastane yarn, ensuring stability through polyester construction, enabling stretch through spandex integration, and managing moisture through engineered knit structure. This multi-functional single layer replaces traditional multi-layer constructions, reducing manufacturing complexity while delivering comprehensive functional performance.
2Reliability
If traditional multi-layer construction is used to provide support and stability, then functional attributes are achieved, but the garment lacks harmonious integration of contrasting attributes
Solution Approach 1:
The patent applies local quality by creating zones of different functional characteristics within the single layered fabric. Different areas of the garment can have varying densities of elastane yarn, polyester construction, and spandex integration to provide localized compression, support, and stretch properties. This allows contrasting attributes to coexist harmoniously in appropriate zones, such as higher compression in support areas and greater stretch in mobility areas.
3Manufacturing precision
If selective heating is applied to create three-dimensional profiles and lock in zones, then fit and support are improved, but energy consumption and processing time increase
Solution Approach 1:
The patent utilizes parameter changes by applying selective thermal energy to induce phase changes in thermoplastic yarns within the fabric. The heating process temporarily softens specific zones, allowing the fabric to be molded into three-dimensional profiles that conform to body contours. Once cooled, the thermoplastic yarns solidify, locking in the desired shape and providing structured support. This targeted thermal parameter change achieves precise fit and support while minimizing overall energy consumption compared to continuous heating or multi-step mechanical processes.
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 method enables the creation of ultra-high-performance apparel with stable support, compression, and comfort in a single layer, maintaining moisture management properties across the garment while allowing for customizable fit and performance, such as in sports bras with localized support zones.
Implementation Method 1
forming the structure of the single layer of textile material using selective heating to provide material support
Implementation Method 2
The selectively heated portions of the textile material provide at least one of fit or support to the garment
Data Source
AI summary
Various textile materials and method of manufacturing the same are provide. A method of single layer garment includes providing a single layer of textile material with low melt yarn. The method also includes forming the structure of the single layer of textile 5 material using selective heating to provide material support. The textile material are formed via at least one of a molding machine or a robotic hot air machine.