Tri-layer knit fabric single process thermal protection
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Solution Overview
Problem
The construction of multilayer thermal textile members, such as blankets and sleeves, is costly due to the need for separate manufacturing operations and secondary processes to join layers together.
Innovation Solution
A knit fabric with an outer, intermediate, and inner layer, each knit from different yarns with distinct stitch types, is constructed in a single knitting process, forming a tubular protective sleeve with integrated layers that provide a durable, heat-resistant, and abrasion-resistant barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate layers are constructed in separate knitting operations and then joined together, then the thermal protective member can be formed with multiple functional layers, but the manufacturing cost increases and the production time extends
Solution Approach 1:
The patent merges the construction of multiple functional layers (outer layer, intermediate layer, inner layer) into a single knitting operation. The knitting machine simultaneously knits all three layers together in one process, eliminating the need for separate manufacturing operations and secondary joining processes. This resolves the contradiction by achieving multi-layer thermal protection without increasing manufacturing complexity or cost.
Solution Approach 2:
The single knitting machine and process are designed to perform multiple functions: constructing the outer layer, intermediate layer, and inner layer simultaneously, and automatically joining them together. This multi-functional approach eliminates the need for separate specialized operations for each layer and joining process, thereby reducing manufacturing cost and complexity while maintaining reliable thermal protective performance.
2Reliability
If separate layers are constructed and joined through secondary operations, then the thermal protective member can be assembled, but the production time increases
Solution Approach 1:
The construction of separate layers and their joining operations are merged into a single simultaneous knitting process. The knitting machine creates all three layers and joins them together in one continuous operation, eliminating the time required for sequential layer construction and secondary joining operations. This directly addresses the productivity issue by significantly reducing total production time while maintaining structural integrity.
Solution Approach 2:
The knitting process operates continuously to construct all layers and join them without interruption. The machine performs layer construction and joining actions in an uninterrupted sequence within a single operational cycle, eliminating idle time between separate operations. This continuous action approach maximizes production speed while ensuring proper structural integrity through consistent knitting tension and pattern.
3Adaptability or versatility
If multiple separate manufacturing operations are used to construct layers, then each layer can be optimized with specific yarns and stitches, but the overall manufacturing process becomes more complex and costly
Solution Approach 1:
The patent combines multiple manufacturing operations into a single knitting process that can handle different yarn types and stitch patterns for each layer simultaneously. The knitting machine is configured to knit the outer layer, intermediate layer, and inner layer with their respective optimized yarns and stitches all in one operation, eliminating the need for separate specialized manufacturing steps for each layer.
Solution Approach 2:
The single knitting machine is designed with universal capabilities to process multiple yarn types (metallic, synthetic, natural) and apply different stitch patterns to different layers within the same operational framework. This multi-functional design allows full customization of layer properties without requiring separate specialized equipment or processes, thereby reducing overall manufacturing complexity while maintaining adaptability.
Data Source
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AI summary
A knit fabric, protective sleeve and glove constructed therefrom has three knit layers knit constructed and knit to one another in a single knitting operation to provide the fabric as a single piece of knit material. The fabric includes an outer layer, an inner layer and an intermediate layer sandwiched between the outer and inner layers. The outer layer is knit with a first yarn, the inner layer is knit with a second yarn and the intermediate layer is knit with a third yam in looped fashion about at least some of the first and second yarns to provide an integrally knit structure having three layers knit stitched together in a single knitting process.