Single-Process Knitted Textile Embroidery for Lower Manufacturing Costs
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Solution Overview
Problem
Existing textile embroidery processes require separate machinery for forming the base textile layer and adding embroidery elements, leading to inefficiencies and increased manufacturing costs, while conventional integration of embroidery patterns in textiles often compromises comfort and durability.
Innovation Solution
A textile component is formed through a single knitting process that integrates a knitted component with a pocket and embroidered elements, using a spacing element to separate the embroidery from the base layer, allowing for enhanced comfort and durability by positioning the embroidery in high-stress areas and incorporating cushioning elements for improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate machinery is used for forming the base textile layer and adding embroidery elements, then manufacturing flexibility is maintained, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The patent combines the base textile layer formation and embroidery element integration into a single knitting machine process. The knitting machine simultaneously produces the base layer and incorporates embroidery elements through integrated mechanisms, eliminating the need for separate embroidery machinery and subsequent assembly steps, thereby significantly improving manufacturing efficiency
2Reliability
If conventional integration of embroidery patterns is used, then manufacturing simplicity is maintained, but comfort and durability are compromised
Solution Approach 1:
The patent segments the textile structure into distinct base layer and embroidery element components that are integrated during knitting. This segmentation allows each component to be optimized independently - the base layer for comfort and the embroidery elements for durability - while maintaining manufacturing simplicity through a single integrated process
Solution Approach 2:
The patent applies different material properties and structural characteristics to different regions of the textile. The base layer uses materials optimized for comfort and breathability, while the embroidery elements use materials optimized for durability and stress resistance. This local differentiation of quality is achieved through the integrated knitting process without complicating manufacturing
3Reliability
If embroidery elements are positioned in high-stress areas, then durability is improved, but comfort may be compromised
Solution Approach 1:
The patent strategically positions embroidery elements in high-stress areas where durability is most needed, while using the base layer material properties to maintain comfort in contact zones. The integrated structure allows the embroidery elements to reinforce stress points without compromising the overall comfort characteristics of the textile
Solution Approach 2:
The patent creates a composite textile structure combining the base layer material with embroidery element materials. This composite construction allows the embroidery elements to provide durability in high-stress areas while the base layer material maintains comfort properties, achieving both durability and comfort simultaneously
Data Source
AI summary
A textile component may include a knitted component with a first knit layer, a second knit layer, and a pocket, where the pocket is located between the first knit layer and the second knit layer. A spacing element may be included, where the spacing element is located within the pocket. An embroidered element on an exterior surface of the first knit layer may be included, where the embroidered element extends through the first knit layer but does not extend through the second knit layer. The textile may also include a cushioning area that is elevated relative to a base portion of the knitted component. An emblem formed by the embroidered element is located within the cushioning area.