Flush Apparel Patch Repair for Damaged ePTFE Fabric
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Solution Overview
Problem
Current methods for repairing damaged outdoor apparel, particularly those made from expanded polytetrafluoroethylene (ePTFE) such as GORE-TEX fabric, are costly and yield less than desirable results.
Innovation Solution
A method for repairing apparel by removing damaged portions and replacing them with a patch that includes a layer extending across an aperture, which can be flush or projecting from the exterior face, and optionally backed by a substrate, using thermoplastic or thermoset materials that are embossed to match or customize the appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current repair methods are used for damaged ePTFE apparel, then the repair cost is reduced, but the repair quality and durability are insufficient
Solution Approach 1:
The patent applies parameter changes by heating the thermoplastic layer to its melting point or above, transforming it from a solid state to a molten state that can flow and fill the aperture. This temperature parameter change enables the material to conform to the damaged area and bond with the surrounding fabric, achieving high-quality repairs that match the original apparel properties.
Solution Approach 2:
The patent uses composite materials by combining a thermoplastic or thermoset layer with a substrate material. This composite structure provides both the bonding capability of the thermoplastic/thermoset material and the structural support of the substrate, creating a durable repair that maintains the waterproof and breathable properties of the original ePTFE apparel.
2Reliability
If a patch is applied to repair large damaged regions, then the repair effectiveness is improved, but the appearance and texture matching becomes difficult
Solution Approach 1:
The patent applies local quality by embossing the layer with the specific texture of the apparel panel at the exact location of the aperture. This localized texturing ensures that the repaired area matches the surrounding fabric's appearance and feel, making the repair imperceptible. The embossing process transfers the original fabric's surface characteristics to the patch material.
Solution Approach 2:
The patent uses copying by embossing the layer with the texture of the apparel panel, creating a replica of the original surface characteristics. This copying of the fabric's texture and pattern allows the repair to blend seamlessly with the surrounding area, achieving precise appearance matching.
3Manufacturing precision
If the layer is deformed into the aperture to be flush with the exterior face, then the appearance is improved, but the material flow and filling control becomes challenging
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the thermoplastic layer during deformation. By heating the layer to its melting point or above, the material becomes sufficiently fluid to flow into and fill the aperture completely. The temperature parameter control enables precise manipulation of material viscosity, allowing the layer to conform exactly to the aperture boundaries and emerge flush with the exterior face.
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 method allows for fast, cost-effective repair of larger damaged regions, reduces waste, and enables customization while maintaining the apparel's waterproof and breathable properties.
Implementation Method 1
heating the thermoplastic layer to a temperature above its melting point so as to melt the thermoplastic layer
Implementation Method 2
pressing the molten thermoplastic layer into the aperture with a repair tool
Implementation Method 3
cooling the thermoplastic layer so as to set the thermoplastic layer
Implementation Method 4
heating the thermoplastic layer to a temperature above its melting point so as to soften the thermoplastic layer
Implementation Method 5
pressing the embossing panel against the exterior face of the patched apparel panel
Data Source
AI summary
An apparel may include a panel having an apparel panel with an aperture extending through the panel from an interior face to an exterior face of the apparel panel. A patch extends opposite the apparel panel and across the aperture on the interior face of the apparel panel. The patch may include a layer joined to portions of the apparel panel about the aperture and filling the aperture so as to be flush with the exterior face of the apparel panel.