UV-Blocking Fabric via Double Knit Structure
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Solution Overview
Problem
There is a need for a UV protecting fabric that provides significant and long-term UV protection to human skin without harming human health or the environment, while also ensuring comfort and strength for the wearer.
Innovation Solution
The development of an ultraviolet blocking fabric composed of 89% polyester and 11% spandex, with at least one of the warp or weft yarns being an elastane yarn, arranged in a double knit or interlock configuration to achieve a UPF rating of at least 49 without the use of conventional laundry additives or harmful chemical finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional chemical compounds are coated on fabric surface to block UV rays, then UV protection is improved, but human health and environment are negatively affected
Solution Approach 1:
The invention extracts and eliminates harmful chemical compounds from the fabric treatment process. Instead of coating fabric with conventional UV-blocking chemicals, the patent uses a chemical-free finishing process that relies on physical structure and natural fiber properties to achieve UV protection, thereby removing the source of health and environmental harm while preserving the protective function
Solution Approach 2:
The invention converts the limitation of natural fibers (lower inherent UV protection compared to synthetic fibers) into a benefit by utilizing the natural structure and composition of cotton and other natural fibers to achieve effective UV protection without chemical treatments. The natural imperfections and fiber characteristics that would normally reduce protection are leveraged to create a safe, chemical-free protective barrier
2Object-affected harmful factors
If fabric is made with tight weave pattern to block UV rays, then UV protection is improved, but fabric comfort and breathability are reduced
Solution Approach 1:
The invention applies different weave densities to different areas or layers of the fabric structure. By creating variations in local weave tightness, the fabric achieves effective UV blocking in critical areas while maintaining breathability and comfort in other regions, allowing simultaneous optimization of protection and comfort properties
Solution Approach 2:
The invention combines multiple natural fiber types (cotton, linen, wool, silk) with different inherent UV-blocking properties and breathability characteristics. This composite approach allows the fabric to achieve superior overall UV protection while maintaining comfort, as each fiber type contributes its unique properties to the blend
3Object-affected harmful factors
If fabric is treated with UV-blocking chemical finishes to achieve high UPF rating, then UV protection is improved, but fabric strength and durability are reduced
Solution Approach 1:
The invention incorporates UV protection properties into the fabric during the manufacturing and finishing stages, before the fabric is put into service. By establishing the protective structure and composition upfront through careful fiber selection and construction, the fabric maintains its strength and durability throughout its service life without relying on degradable chemical coatings
4Object-affected harmful factors
If fabric uses high polyester content to improve UV protection, then UV blocking is improved, but fabric comfort and softness are reduced
Solution Approach 1:
The invention creates composite fabric structures combining natural fibers (cotton, linen, wool, silk) with synthetic UV-blocking fibers in optimized ratios. This composite approach leverages the comfort and softness of natural fibers while incorporating the superior UV-blocking properties of synthetic fibers, achieving both comfort and protection simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fabric achieves excellent UV protection with a UPF rating of at least 49, maintaining its protective properties after 40 laundering cycles, while providing comfort, strength, and breathability, thus addressing the need for a safe and effective UV protecting fabric.
Implementation Method 1
The combination of the warp yarn and the weft yarn arranged to form the fabric comprises an ultraviolet protection factor (UPF) rating of at least 49 in accordance with AATCC 183
Data Source
AI summary
An improved ultraviolet (UV) blocking fabric that has an ultraviolet protection factor (UPF) rating of at least 49 in accordance with AATCC 183. The fabric does not require ultraviolet protecting coating(s) or finish(es) or such other treatment for achieving the desired ultraviolet protecting efficiency. Further, the fabric affords maintenance of the UPF rating even after the fabric has been subjected to several laundering cycles.