Knitted Fabric With Thick-and-Thin Composite Yarn for Cotton-Like Texture
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Solution Overview
Problem
Existing polyester filament fibers lack cotton-like appearance, texture, snagging resistance, and adequate see-through-preventing and water absorbing/quick drying properties.
Innovation Solution
A knitted fabric comprising a composite yarn of non-crimped thick and thin yarn and crimped yarn, aligned and interlaced, with specific weight ratios and configurations, utilizing polyester or nylon fibers and matting agents for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polyester filament fibers are used, then productivity and ease of manufacture are improved, but appearance, texture, and snagging resistance deteriorate compared to natural fibers
Solution Approach 1:
The patent applies local quality by creating thickness unevenness in specific portions of the yarn. The yarn contains both thick portions and thin portions along its length, with the thick portions providing bulk and the thin portions allowing light penetration for a natural appearance. This local variation in diameter mimics the irregular structure of natural fibers while maintaining polyester's manufacturing advantages.
Solution Approach 2:
The patent employs asymmetry by introducing deliberate irregularities in the yarn structure. The thickness unevenness creates an asymmetric cross-sectional profile along the yarn length, and the crimped structure introduces asymmetric undulations. These asymmetric features break the uniformity of conventional polyester filament, creating a more natural, less synthetic appearance.
2Manufacturing precision
If uniform thickness polyester yarn is used, then manufacturing precision is improved, but cotton-like appearance and texture deteriorate
Solution Approach 1:
The patent deliberately introduces local quality variations through thickness unevenness in the yarn. Specific portions of the yarn are made thicker or thinner in a controlled manner, creating regions with different optical and tactile properties. This local variation is key to achieving the cotton-like appearance while maintaining overall manufacturing control.
Solution Approach 2:
The patent applies parameter changes by systematically varying the yarn diameter along its length. The thickness unevenness parameter is controlled to fall within specific ranges (with thin portions being thinner and thick portions being thicker by specific percentages). This controlled parameter variation achieves the desired natural appearance while maintaining manufacturing precision through defined specifications.
3Shape
If crimped yarn structure is added to achieve cotton-like appearance, then appearance and texture are improved, but snagging resistance may deteriorate
Solution Approach 1:
The patent employs composite materials by combining multiple yarn types with different properties. The composite yarn structure integrates crimped portions (for appearance) with smoother thick portions (for strength and snagging resistance). This composite approach allows each component to contribute its advantageous properties to the overall yarn performance.
Solution Approach 2:
The patent applies local quality by distributing crimped and smooth sections alternately along the yarn length. The crimped portions provide the desired cotton-like appearance and texture, while the smooth thick portions provide structural integrity and snagging resistance. This spatial distribution of different local qualities resolves the contradiction between appearance and strength.
4Illumination intensity
If high density knitting is used to prevent see-through, then see-through-preventing properties are improved, but breathability and comfort deteriorate
Solution Approach 1:
The patent applies local quality through the thick and thin portion structure of the yarn. The thick portions act as light-blocking elements that prevent see-through in critical areas, while the thin portions create micro-gaps that allow air circulation. This local differentiation enables simultaneous achievement of opacity and breathability without requiring high overall knitting density.
Data Source
AI summary
A problem of the present invention is to provide a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties. The solution is to obtain a composite yarn using a thick and thin yarn and a crimped yarn and to obtain a fabric, if desired.