Toe Seam Bulk Reduction in Hosiery Knitting

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Solution Overview

Problem

Automated toe seam formation in hosiery has not achieved the comfort levels of traditional hand-linking methods, with attempts to modify the seam resulting in either bulkiness or limited comfort improvements.

Innovation Solution

A method involving specific knit constructions and yarn combinations, including continuous filament yarns, to create a comfortable and non-intrusive toe seam, using a circular knitting machine and seaming process that minimizes bulk and maximizes comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hand-linking is used to close the toe, then comfort is improved, but productivity deteriorates

Engineering Contradiction:

ImprovecomfortVSAvoidproductivity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical hand-linking process with an automated knitting machine system that uses programmed needle selection and yarn feeding to create the toe seam closure, thereby maintaining comfort while dramatically improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operational parameters of the knitting machine by selectively inactivating specific needles in the toe region and using separate yarn feeds to create a closed toe structure, transforming the traditional open toe knitting process into an automated seam-forming process

Inventive Principle:

Principle #35Parameter changes

2Strength

If additional seaming threads are used to improve seam strength, then strength is improved, but comfort deteriorates due to bulkiness

Engineering Contradiction:

Improveseam strengthVSAvoidcomfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent merges the seam-forming function with the existing knitting process by using the knitting machine's needles and yarn feeds to create the toe closure, eliminating the need for separate seaming threads and their associated bulkiness while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the seaming function from the traditional post-knitting seaming process and integrates it directly into the knitting process itself, removing the need for additional seaming threads that cause bulkiness

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If automated seaming is implemented to improve productivity, then productivity is improved, but comfort deteriorates

Engineering Contradiction:

ImproveproductivityVSAvoidcomfort

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent replaces traditional automated seaming mechanisms with a modified knitting machine system that uses programmed needle selection and yarn feeding to create the toe closure, achieving both high productivity and comfort comparable to hand-linking

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the knitting machine's operational parameters by selectively controlling individual needles and yarn feeds to create a comfortable toe seam structure, demonstrating that automated parameter control can achieve hand-linking quality at industrial productivity levels

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8156768B2System and method of forming a toe seam

Publication Date: 2012.04.17 HBI BRANDED APPAREL ENTERPRISES LLC

AI summary

An article of hosiery having a toe seam has been developed. The hosiery includes a foot portion and a first circumferential toe portion having a first stitch length. A second circumferential toe portion can be adjacent the first toe portion. The second circumferential toe portion has at least two knitted courses with each of the at least two knitted courses having a second stitch length that is less than the first stitch length. There is at least one thread in the first circumferential toe portion that forms the toe seam.