Advanced design of 3D knitted padding for wearable cushioning in knee protector

Wearable cushioned products protect the body during sporting activities or work-related activities. Cushioning paddings made of elastomeric materials are used to absorb impact forces. The paddings are usually inelastic, which could be challenging to accommodate the movement of knee joints and lead to displacement. In this study, a new knitted composite which consists of soft surface layers, a shock absorption middle layer made of monofilament and silicone inlays and additional elastic inlays in the surface layer to accommodate the body contours is developed. The three-layer structure is knitted as 3D knee paddings in a single process. The air permeability, mechanical properties, and subjective wear comfort of the knitted paddings and their impact on muscle activity are evaluated and compared with those of commercially available elastomeric knee paddings. The results show that the knitted padding with a silicone inlay can better absorb impact forces than that without the inlay showing a 14% increment. The 3D knitted padding is perceived to be more soft, elastic and bendable, with a better fit and wear comfort, with more slip resistance than the elastomeric padding with a similar thickness. The outcomes can act as a good reference for the development of textile cushioning materials.