Sliver-Knit Insulating Fabric with Dual-Sided Pile
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulating fabrics face issues such as inconsistency, shedding, degradation, and the need for quilting to maintain position, particularly in yarn and fiberfill-based materials, which affect thermal insulation and durability.
Innovation Solution
A sliver-knit insulating fabric is developed, featuring a knitted base material with secured tufts of fibers forming pile portions on both sides, using a low melt yarn and low denier fibers, which are heat-set to ensure dimensional stability and consistent weight distribution, achieving improved thermal insulation and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If yarn based insulating fabrics are used, then thermal insulation is provided, but the knitted yarn degrades to form pile and insulating material penetrates through outer layers
Solution Approach 1:
The patent changes the fundamental parameter of insulating material from yarn-based to fiber-based construction. Individual fibers are tufted through the knitted base material and secured with knit-over stitches, preventing fiber degradation and penetration while maintaining thermal insulation properties
Solution Approach 2:
The patent creates a composite structure combining a knitted base material with tufted fiber sections. The fibers are embedded within and secured to the base material through interlocking stitches, forming a unified composite that prevents fiber loss and maintains structural integrity
2Reliability
If fiberfill based insulating fabrics are used, then thermal insulation is provided, but the insulating material sheds from the base fabric
Solution Approach 1:
The knitting machine automatically performs the function of securing fibers to the base material through the knitting process itself. The knit-over stitches are formed as an integral part of the fabric construction, eliminating the need for separate attachment processes and ensuring fibers remain securely embedded
Solution Approach 2:
The patent creates a composite structure where fibers are tufted through and secured to the knitted base material. The interlocking knit-over stitches create a unified composite that prevents fiber shedding while maintaining the insulating properties of the fiber fill
3Ease of manufacture
If insulating fabric is made without quilting, then manufacturing simplicity is improved, but the insulating fabric cannot maintain proper location relative to outer layers
Solution Approach 1:
The knitted base material itself provides the anchoring function that would otherwise require a separate quilting process. The knit-over stitches that secure the fiber tufts also anchor the entire insulating layer to the base material, allowing the fabric to maintain its position without additional quilting steps
4Reliability
If insulating fabric uses higher weight material, then thermal insulation is improved, but weight per unit area increases
Solution Approach 1:
The patent changes the construction parameter from dense yarn weaving to a开放式 knitted base with tufted fibers. This open structure provides thermal insulation through air pockets between fibers while maintaining lower weight, achieving high insulation-to-weight ratio
Solution Approach 2:
The knitted base material with tufted fibers creates a porous structure with air pockets distributed throughout. This porosity provides thermal insulation by trapping air, which is a poor heat conductor, while keeping the overall fabric weight low
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 enhanced thermal insulation, dimensional stability, and consistent weight distribution, overcoming the limitations of existing insulating fabrics by securing fibers within the knitted base material and heat-setting for improved performance.
Implementation Method 1
the knitted base material and plurality of tufts of fibers have a combined weight per unit area of less than 200 g/m2... the knitted base material is a low melt yarn... heat-set to ensure dimensional stability
Data Source
AI summary
A sliver-knit insulating fabric is disclosed that has pile extending from both sides of a knitted base material with the insulating fabric having a weight per unit area of less than 200 g/m2. The pile is formed from a plurality of tufts of fibers secured within the knitted base material. The tufts of fibers define a plurality of end portions extending from the knitted base material with a first portion of the end portions extending from a first side of the knitted base material to form a first pile portion and a second portion of the end portions extending from a second side of the knitted base material to form a second pile portion. A method of forming the sliver-knit insulating fabric is also disclosed.