3D Shaped Fabric Structure Using Differential Shrinkage
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Solution Overview
Problem
Conventional mesh sheet-based object supporting surfaces, when used with planar metal frames, become planar and require intricate assembly to optimize shape and elasticity, leading to high costs and difficulties in sewing or bonding different materials and fabrics.
Innovation Solution
A three-dimension fabric with heterogeneous yarn and/or fabric structures that differ by shrinkage and tension, allowing for heat-set formation of curved surfaces without complex frames, enabling easy optimization of shape and elasticity at each portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a planar metal frame and mesh sheet are used to create an object supporting surface, then the structure is simple and easy to manufacture, but the supporting surface becomes planar and cannot fit the three-dimensional shape of the body, causing great elastic deformation and continuous reaction force
Solution Approach 1:
The patent applies parameter changes by varying the yarn composition, knitting structure, and tension parameters across different regions of the fabric to create heterogeneous portions with different shrinkage characteristics. This allows the fabric to form three-dimensional curved surfaces that conform to body shapes while maintaining ease of manufacture through a single integrated fabric structure rather than assembling multiple planar components.
Solution Approach 2:
The patent transitions from a two-dimensional planar fabric to a three-dimensional shaped fabric by introducing curvature and volume through differential shrinkage. The heterogeneous portions of the fabric are formed into three-dimensional shapes with curved surfaces, adding a third dimension that enables the supporting surface to fit the contoured shape of the body.
2Shape
If different materials and fabrics are assembled by sewing or bonding at each portion on a supporting body to optimize shape and elasticity, then the shape and elasticity can be optimized, but the cost increases and the difficulty in sewing or bonding mesh sheets arises
Solution Approach 1:
The patent merges multiple functional portions into a single integrated fabric structure. Instead of assembling separate pieces of different materials through sewing or bonding, the invention creates one continuous fabric with heterogeneous portions that have different yarn compositions and knitting structures. This eliminates the need for complex assembly operations while maintaining optimized shape and elasticity at each portion.
Solution Approach 2:
The patent creates a universal fabric structure that performs multiple functions within a single component. The heterogeneous fabric serves both as the supporting surface and as the shape-defining element, eliminating the need for separate assembly of multiple specialized components. Each portion of the fabric is optimized for its specific function while being part of an integrated whole.
3Object-affected harmful factors
If a planar object supporting surface is used with well cushioning, then cushioning comfort is achieved, but the surface elastically deforms greatly to support prominent portions of the body, generating continuous reaction force
Solution Approach 1:
The patent applies local quality by creating heterogeneous portions with different yarn compositions, knitting structures, and tension characteristics at specific locations on the fabric. This allows each portion to have optimized local properties that match the requirements of the underlying body portion, providing appropriate cushioning and support without excessive elastic deformation. The local variations in fabric structure enable the surface to conform to body contours while maintaining comfort.
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 can be easily formed into desirable three-dimensional shapes with varying elasticity, air permeability, and texture, reducing assembly complexity and costs while providing a comfortable and flexible supporting surface.
Implementation Method 1
the fabric for forming the fabric surface includes at least one heterogeneous portion of which yarn and/or fabric structure is different from a peripherally-surrounding adjacent portion, wherein the heterogeneous portion and the peripherally-surrounding adjacent portion are formed in three-dimensional shapes having curved surfaces different from each other
Implementation Method 2
the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes different to each other by a difference of a shrink and/or tension between the heterogeneous portion and the adjacent portion
Data Source
Figure 1(A)~1(C)
Figure 2(A)~2(C)
Figure 3(A)~3(C)
AI summary
A three-dimension fabric by which a three-dimension fabric surface can be formed by supporting the fabric edges by a frame member and stretching the fabric, characterized in that the fabric per se, which constitutes the fabric surface, is provided with at least one heterogeneous portion that is different at least in yarn type and/or fabric structure type from the adjacent portion. Thus, provided is the three-dimension fabric which can be easily made into a construct of a desirable shape without using a frame having a complicated shape, and in which the shape of an object supporting surface, the elasticity at each portion, etc., can be easily optimized.