Therapeutic Stocking Heel Pocket Knit Structure
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Solution Overview
Problem
Compression stockings often experience excessive stress on yarns and knit structures at the heel, leading to wrinkling in the malleolar region, which can cause dermatological irritation, and existing solutions that address these issues compromise the integrated knit stitch format and manufacturing efficiency by introducing seams or patches.
Innovation Solution
A therapeutic compression stocking with a seamless design featuring a graduated compression force distribution across the leg, foot, and arch portions, utilizing a knitting machine with needle selection capability to produce an oversized heel pocket with looser stitch loops and multi-ribbed formats to prevent wrinkling and minimize tension on yarns, ensuring efficient production without seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If compression stockings are designed with tight knit structures to provide compression, then compression effectiveness is improved, but excessive stress is produced on yarns and knit structures at the heel during donning
Solution Approach 1:
The patent applies different knit structures to different regions of the stocking: a tighter knit structure in the foot and lower leg regions to provide necessary compression, and a looser knit structure specifically at the heel region to reduce stress during donning. This localized variation in knit density allows the stocking to provide compression where needed while protecting vulnerable areas from excessive stress.
2Productivity
If the stocking is designed with seamless integrated knit stitch format, then manufacturing efficiency is improved, but wrinkling occurs in the malleolar region over the ankle
Solution Approach 1:
The patent introduces a specific knit structure modification in the malleolar region (ankle area) to prevent wrinkling. This localized structural change creates a smoother surface in the area prone to folding, eliminating the dermatological irritation caused by wrinkles while preserving the seamless integrated knit format for efficient manufacturing.
3Strength
If a stocking gap is provided in the heel area to reduce stress, then yarn stress is reduced, but the heel is exposed and the gap boundary stitching is stressed
Solution Approach 1:
Instead of creating a gap (binary presence/absence of material), the patent changes the knit density parameter in the heel region. By using a looser knit structure, the fabric maintains continuous coverage protecting the heel, while the reduced density lowers the stress on yarns during donning. This parameter change allows simultaneous achievement of stress reduction and heel protection.
4Reliability
If patches are sewn into problem areas to prevent wrinkling and stress, then local protection is improved, but the stocking cannot be produced in integrated knit stitch format
Solution Approach 1:
The patent merges the wrinkle-prevention function directly into the main knit structure by incorporating a specific knit pattern (such as a ribbed or interlocked structure) in the malleolar region. This eliminates the need for separate patches while maintaining the integrated seamless construction, allowing the stocking to be produced in one continuous knit process with enhanced functionality built-in.
Data Source
AI summary
A therapeutic compression stocking is knitted in an integrated knit format to have an oversized heel pocket from which an ankle arch portion extends that is knitted in a rib stitch format that is free of wrinkles when donned. The foot portion has a constant compression force while the leg portion has a graduated compression force. The leg portion compression force being less than the foot portion compression force.