Seamless Undershirt Knitting via Single Tubular Cutting
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Solution Overview
Problem
The existing procedure for manufacturing undershirts using seamless technology with circular machines is inefficient, resulting in high material waste, long production times, and increased energy and disposal costs due to the need for multiple tubular elements.
Innovation Solution
A procedure that utilizes a single tubular element with circular knitting machines, where cutting lines are strategically drawn and excess material is eliminated to create the undershirt components, reducing material consumption and processing time while simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple tubular elements are constructed to create the undershirt, then the garment can be assembled with proper fit and structure, but the manufacturing time and material consumption increase significantly
Solution Approach 1:
The patent merges multiple tubular elements (body, sleeves, collar) into a single tubular element that is knitted continuously. The single element is then cut into sections and assembled to form the complete undershirt, eliminating the need to construct and assemble multiple separate tubular elements while maintaining proper fit and structure.
Solution Approach 2:
The single tubular element serves multiple functions simultaneously - it provides the body, sleeves, and collar of the undershirt. By designing the single element to include all necessary portions with appropriate cutting lines, the patent achieves multi-functionality that reduces manufacturing complexity and time.
2Reliability
If multiple tubular elements are constructed to create the undershirt, then the garment can be assembled with proper fit and structure, but the raw material consumption increases by up to two-thirds
Solution Approach 1:
The patent combines multiple tubular elements into one continuous tubular element that is knitted in a single operation. This single element is then cut into the necessary sections (body, sleeves, collar) using cutting lines, thereby reducing raw material consumption by up to two-thirds compared to constructing multiple separate elements.
Solution Approach 2:
The patent optimizes material usage by cutting the single tubular element along specific cutting lines to create the necessary garment portions. The cutting process is designed to minimize waste, and any excess material is recovered or reused, further reducing overall raw material consumption.
3Reliability
If multiple tubular elements are constructed and assembled, then the undershirt can be manufactured with proper components, but the energy costs and disposal costs increase
Solution Approach 1:
The patent merges the construction of multiple tubular elements into a single knitting operation. This reduces the total energy consumption associated with running multiple knitting cycles, cutting operations, and assembly processes, while also reducing disposal costs for off-cut materials.
Solution Approach 2:
The patent implements a system to recover and reuse off-cut materials from the cutting process. By collecting and reusing these materials, the patent reduces disposal costs and minimizes waste, thereby lowering overall energy and disposal expenses.
4Loss of substance
If a single tubular element is used to create the undershirt, then material consumption is reduced by up to two-thirds, but the cutting and joining process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-marking cutting lines on the single tubular element during the knitting process. These cutting lines are established in advance using graphic programs, so that when the element is cut and assembled, the process is streamlined and less complex than managing multiple separate elements.
Solution Approach 2:
The patent segments the single tubular element into appropriate portions (body, sleeves, collar) by cutting along pre-defined cutting lines. This segmentation approach simplifies the overall process compared to constructing multiple elements, as it involves cutting one element into sections rather than assembling multiple complete elements.
Data Source
AI summary
A procedure for manufacturing an undershirt provided with a trunk, two sleeves, and a collar, includes providing a circular knitting machine using seamless technology; constructing a first tubular fabric element using said machine, where said first tubular element comprises a front side, a rear side, an upper edge, and a lower edge; drawing cutting lines on said first tubular element, during construction; cutting said first tubular element along said cutting lines to separate portions of fabric of said first tubular element to create flaps of fabric belonging to the front side and to the rear side of the first tubular element; and joining with stitches the flaps of said portions of fabric obtained with said cutting lines to create at least the two sleeves and the trunk of said undershirt from said first tubular element.