Zoned Moisture-Management Garment With Seamless Denier Differentials

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Solution Overview

Problem

Designing apparel that effectively manages perspiration and cooling during exertion is challenging due to varying perspiration rates across different body zones and activity types, with existing methods requiring bulky and uncomfortable seams from stitching different textile panels.

Innovation Solution

A zoned moisture management garment using denier differential fabric with aerographic yarn compositions, where one layer has a dissolvable yarn that can be selectively removed to increase airflow and porosity in specific zones, while the other layer has a non-dissolvable yarn for enhanced moisture management, promoting skin dryness and evaporative cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different textile panels are stitched together to create zoned moisture management garments, then moisture management properties can be tailored to different body zones, but bulky and uncomfortable seams are introduced

Engineering Contradiction:

Improvemoisture management propertiesVSAvoidcomfort

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The garment is divided into multiple zones with different moisture management properties by incorporating dissolvable yarns in specific patterns during the knitting process, allowing each zone to be optimized for different perspiration rates without physical seams

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple fabric layers with different denier yarns are combined into a single integrated knit structure, where the dissolvable yarns create zone differentiation while maintaining seamless construction for comfort

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

Engineering Contradiction:

Improvemoisture management propertiesVSAvoidmanufacturing process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The dissolvable yarns are incorporated into the fabric structure during the initial knitting process, and the zoning pattern is predetermined through selective placement of these yarns, eliminating the need for subsequent stitching operations to create zones

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The dissolvable yarns are selectively removed through dissolution in specific zones after knitting, creating the zoned structure directly in the fabric without requiring assembly of separate panels through stitching

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If dissolvable yarn is removed to increase airflow and porosity in specific zones, then ventilation is improved, but fabric integrity may be compromised

Engineering Contradiction:

ImproveventilationVSAvoidfabric integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The dissolvable yarns are placed only in specific zones where enhanced ventilation is needed, while non-dissolvable yarns maintain fabric integrity in other areas, creating local variations in porosity without compromising overall structure

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The fabric is constructed as a composite of dissolvable and non-dissolvable yarns with different denier values, where the non-dissolvable component provides structural integrity and the dissolvable component creates ventilation zones when removed

Inventive Principle:

Principle #40Composite materials

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 solution allows for tailored moisture management and cooling properties in different zones without bulky seams, improving comfort and performance by optimizing ventilation and sweat management based on individual sweat profiles and contact areas.

Implementation Method 1

Surface tension and capillary forces drive the moisture from the wearer's skin to the back layer

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

Moisture then moves from the back layer to the facing layer due to increased surface area of the facing layer. Due to the increased surface area of the facing layer, moisture may be spread out with greater surface area to evaporate

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS9107459B2Aerographics and denier differential zoned garments

Publication Date: 2015.08.18 NIKE INC

AI summary

A zoned moisture management garment is presented, which provides one-way moisture transport from a wearer's body and zones of different moisture management performance. By incorporating dissolvable yarns, removable by a printable paste, with non-dissolvable yarns of different denier per filament, zoned garments with a denier differential mechanism can be created. The zoned garment optimizes evaporative cooling and wicking zones of a garment based upon a sweat profile and contact profile of the wearer.