3D Conformable Induction Heating for Irregular Seam Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional heat presses are ill-suited for bonding non-linear, irregular, or curved seams in clothing articles, often resulting in structural weaknesses due to their planar surfaces.
Innovation Solution
The use of induction heating with a structure having three-dimensional conformability, which encloses ferromagnetic materials, to apply heat directly to adhesives or fabric seams, ensuring effective bonding of irregular seams without physical contact with a heat source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional planar heat presses are used to bond seams, then the bonding process is simple and straightforward, but the bonding quality of irregular or curved seams deteriorates due to inability to conform to complex geometries
Solution Approach 1:
The patent employs a three-dimensional conformable heating structure that can adapt to curved and irregular seam geometries, replacing the traditional flat planar heat press surface. This curved/conformable structure enables effective heat transfer to adhesive on complex seam surfaces while maintaining bonding process simplicity through automated induction heating.
Solution Approach 2:
The heating structure is designed with three-dimensional conformability, allowing it to dynamically adapt its shape to match the specific geometry of the seam being bonded. This dynamic adaptation ensures consistent bonding quality across different seam types (curved, irregular, planar) without requiring multiple specialized tools, thus maintaining ease of manufacture.
2Temperature
If traditional contact-based heat presses are used, then heating can be applied directly to the seam, but the risk of injury or unsafe conditions increases due to direct contact with hot surfaces
Solution Approach 1:
The patent replaces the traditional mechanical contact-based heating system with an induction heating system that uses electromagnetic fields to heat ferromagnetic materials. This substitution eliminates the need for direct contact between the heat source and the seam, removing the safety hazard of hot surface contact while maintaining efficient heating through electromagnetic energy conversion.
Solution Approach 2:
Ferromagnetic materials are introduced as an intermediary medium between the electromagnetic field and the adhesive/seam. The electromagnetic field heats the ferromagnetic material, which then transfers heat to the adhesive indirectly. This intermediary approach enables efficient heat transfer while preventing direct exposure to extreme temperatures, reducing safety risks.
3Use of energy by moving object
If induction heating with ferromagnetic materials is used, then energy consumption is reduced and heating efficiency improves, but the device complexity increases due to integration of electromagnetic fields and ferromagnetic components
Solution Approach 1:
The patent changes the physical parameters of the heating system by introducing ferromagnetic materials with specific magnetic properties that enhance induction heating efficiency. By selecting materials with appropriate magnetic permeability and conductivity, the system achieves superior energy efficiency and localized heating while the modular integration keeps complexity manageable through standardized electromagnetic components.
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 method allows for consistent, uniform heating of irregular seams, enhancing bonding strength, reducing energy consumption, and minimizing the risk of injury or unsafe conditions, while enabling efficient bonding of complex seam patterns.
Implementation Method 1
an electromagnetic field is used to inductively heat a structure having three-dimensional deformability
Implementation Method 2
the electromagnetic field may be used to directly inductively heat an adhesive having ferromagnetic particles
Implementation Method 3
the electromagnetic field is used to inductively heat ferromagnetic materials integrated into targeted portions of fabric
Data Source
AI summary
Methods for bonding a seam using an inductively heated structure are provided. A three-dimensionally conformable structure is placed upon materials at a location of a desired seam for a clothing article. The structure contours to the surface and material as placed. The structure includes a conductive filling that may be inductively heated. The heated structure and conductive filling activate a heat-responsive adhesive at the location and bond the materials to one another to form the desired seam.