Variable Power Zone Spacer Fabric Knitting
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Solution Overview
Problem
Existing garment manufacturing methods, such as lamination or cut-and-sew, are time-consuming and costly, and circular knitting struggles to incorporate variable zones of support and elasticity in a single lightweight and aesthetically appealing undergarment.
Innovation Solution
A circularly knitted spacer fabric with selectively and intermittently knitted elasticized yarns in predetermined zones, allowing for varying moduli of elasticity in the facing and backing layers, which can be programmed using a computer-controlled circular knitting machine to create zones of differing elasticity through yarn color, thickness, and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lamination or cut-and-sew methods are used to create zones of distinct properties, then garment functionality and support are improved, but manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple fabric pieces with distinct properties into a single circularly knitted spacer fabric by selectively incorporating elasticized yarns in specific zones during one continuous knitting process. This merging eliminates the need for separate lamination or sewing steps while maintaining zone-specific functionality for support and modesty.
Solution Approach 2:
The spacer fabric serves multiple functions simultaneously: it provides modesty through its opaque nature, offers support through selectively placed elasticized zones, and enables seamless construction. The single fabric structure performs what previously required multiple specialized components assembled through time-consuming processes.
2Productivity
If circular knitting is used to produce seamless blanks, then manufacturing efficiency and cost are improved, but ability to incorporate variable zones of support and elasticity deteriorates
Solution Approach 1:
The patent applies local quality by selectively knitting elasticized yarns into specific zones of the spacer fabric during circular knitting. Different zones have different yarn compositions - some areas contain elasticized yarns for support while others use standard yarns for flexibility or aesthetic purposes, all within a single seamless knitted structure.
Solution Approach 2:
The circular knitting machine dynamically adjusts yarn selection during the knitting process, switching between different yarn types (elasticized vs. standard) based on the desired zone properties. This dynamic yarn substitution capability allows variable zones to be incorporated directly into the seamless knitted blank without breaking the continuous production process.
3Adaptability or versatility
If multiple pieces of fabric are laminated or sewn together, then garment functionality is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges multiple fabric pieces with different functions (modesty panels, support zones, flexible areas) into a single spacer fabric construction. The facing layer, backing layer, and spacer layers are knitted together in one continuous process with selective elasticized yarn incorporation, eliminating the need for separate lamination or sewing operations to assemble functional zones.
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
This approach enables the creation of garments with tailored zones of support and modesty, reducing manufacturing time and costs by eliminating the need for additional sewing and lamination, while maintaining aesthetics and functionality similar to cut-and-sew garments.
Implementation Method 1
elasticized yarns selectively knitted into a facing layer of the spacer fabric... selectively and/or intermittently knitted in elasticized yarns to create zones of predetermined and variable moduli of elasticity
Data Source
AI summary
A fabric having a first surface, a second surface opposite the first surface and an intermediate surface between the first surface and the second surface is provided. At least one of the first surface and the second surface is knitted with at least one elasticized yarn at at least one predetermined zone to provide a selected zone of elasticity to at least one of the first surface or the second surface of the fabric.