Stitch-Size Controlled Knit Product Compression

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Solution Overview

Problem

Conventional methods for creating compression regions in knitted fabrics, such as socks, result in thicker and harder areas, discomfort due to protruding yarn tails, and uneven compression, which can cause unnecessary compression and discomfort.

Innovation Solution

A circular knitting machine is used to selectively drive sinkers to create stitches of varying sizes on a stitch-by-stitch basis, allowing for precise control of stitch size and placement to form compression regions without unnecessary compression, improving comfort and preventing yarn tails from protruding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a tuck stitch is applied to form a compression region, then the compression region has lower elastic property, but the compression region becomes thicker and harder than surrounding regions

Engineering Contradiction:

Improveelastic propertyVSAvoidthickness and hardness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent applies different stitch sizes locally within the same knitted fabric structure. Small stitches are selectively formed in compression regions while large stitches are used in non-compression regions, allowing differential elastic properties and thickness control without compromising overall fabric uniformity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the stitch size parameter (from large to small) in specific regions to achieve compression effects. By controlling stitch size rather than using tuck stitches, the fabric maintains uniform thickness and softness while creating regions with different elastic properties

Inventive Principle:

Principle #35Parameter changes

2Strength

If elastic material or motif yarn is inserted to form compression region, then compression effect is achieved, but cut yarn tails project from skin-side surface causing discomfort

Engineering Contradiction:

Improvecompression effectVSAvoidprotruding yarn tails

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses stitch size variation (large vs. small stitches) instead of inserting elastic materials or motif yarns. This approach achieves compression effects through structural differences while maintaining a smooth fabric surface without protruding yarn tails or foreign materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts and eliminates the need for inserted elastic materials and motif yarns by using pure stitch size control. This removes the source of protruding yarn tails and foreign material discomfort while maintaining compression functionality

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If compression region is formed on round-by-round basis, then compression structure is simple, but portions that should not be compressed are also compressed unnecessarily

Engineering Contradiction:

Improvecompression structure simplicityVSAvoidunnecessary compression

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent segments the knitted fabric into different stitch size regions (large stitches for non-compression areas, small stitches for compression areas) within the same course. This allows precise spatial control of compression effects, compressing only specific portions while leaving other areas uncompressed

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates local quality differences through stitch size variation, allowing different regions of the fabric to have different elastic properties. Compression is applied locally only where small stitches are formed, preventing unnecessary compression in regions that require full elasticity

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If stitch cam operation is used to make different stitch sizes, then stitch size variation is achieved, but control precision is insufficient on stitch-by-stitch basis

Engineering Contradiction:

Improvestitch size variationVSAvoidcontrol precision

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical stitch cam system with a programmable sinker control system. Individual sinkers can be selectively driven based on precise digital patterns, enabling stitch-by-stitch control precision that mechanical cams cannot achieve

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a dynamic, programmable control system for sinkers that can adapt stitch size on a stitch-by-stitch basis according to digital patterns. This provides flexible, precise control compared to the fixed mechanical cam trajectory

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10094054B1Stitch-size controlled knit product

Publication Date: 2018.10.09 OKAMOTO INDS

AI summary

A knit product includes a compression region and is formed by a circular knitting machine knitting first and second stitches having different stitch sizes in the same course. The second stitch has a smaller stitch size. The second stitch is selectively provided on a stitch-by-stitch basis. The knitting needles have a density of 14 to 24 per inch in a circumferential direction. A face yarn of a knitting yarn has a cotton count larger than 10. A back yarn of the knitting yarn is a covering yarn having a core yarn of polyurethane of 70 denier or less or a man-made fiber of 140 denier or less subjected to texturing. The size difference between the first and second stitches is 0.1 mm to 2.0 mm. The elongation difference between a first-stitch region of the first stitch and a second-stitch region of the second stitch is 20% to 100%.