Elastic Truss Pad Bonding With Breathable Hot-Melt Fleece

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Solution Overview

Problem

Existing bandages with adhesive-coated pads lack elasticity and breathability, leading to reduced wearing comfort and increased difficulty in application due to inelastic seams and poor circumferential flexibility.

Innovation Solution

A method involving an open hot melt adhesive fleece is used to bond a pad cover to an elastic knitted body, ensuring elasticity by maintaining the structure's flexibility and breathability through ventilation channels and alternating channel arrangements, with capacitive heating for bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hot-melt adhesive layer is applied over a large area to bond the pad cover to the knitted body, then the durability and appearance of the bandage are improved, but the elasticity and breathability of the bandage deteriorate

Engineering Contradiction:

Improvedurability of pad attachmentVSAvoidwearing comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The adhesive layer is segmented into discrete adhesive points or regions rather than being applied as a continuous large-area coating. This allows the pad cover to be bonded to the knitted body at specific locations while leaving other areas open and elastic, thus maintaining both durability of attachment and wearing comfort through preserved elasticity and breathability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adhesive properties are localized to specific areas where bonding is required, rather than being distributed uniformly across the entire pad cover. This local application of adhesive ensures strong attachment at critical points while maintaining the elastic and breathable characteristics of the knitted body in non-adhesive areas.

Inventive Principle:

Principle #3Local quality

2Strength

If the pad cover is bonded to the knitted body using a continuous adhesive layer, then the bond strength is improved, but the circumferential elasticity of the bandage deteriorates

Engineering Contradiction:

Improvebond strength between pad cover and knitted bodyVSAvoidcircumferential elasticity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The continuous adhesive layer is replaced by segmented or discontinuous adhesive applications at strategic locations around the pad contour. This segmentation provides sufficient bond strength to secure the pad cover while allowing the knitted body to expand and contract circumferentially in the non-adhesive regions, thus maintaining elasticity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adhesive bonding system is designed to be dynamic rather than rigid, allowing the bonded regions to flex and stretch with the knitted body during bandage application and wear. The adhesive points are positioned and sized to provide strength while accommodating dynamic movement and circumferential expansion.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If seams are used to attach the pad cover to the knitted body, then the manufacturing simplicity is improved, but the durability and appearance deteriorate due to seam wear and chafing

Engineering Contradiction:

Improvesimplicity of attachment methodVSAvoiddurability of pad attachment

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The mechanical seam-based attachment system is replaced with a thermal adhesive bonding system. Instead of using needles and thread that can wear and chafe, the invention uses hot-melt adhesive applied in a controlled manner to bond the pad cover to the knitted body, eliminating seam-related durability issues while maintaining manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a durable, elastic, and breathable bandage with improved comfort and ease of application, maintaining high elasticity and vapor permeability while ensuring a strong bond between the pad cover and knitted body.

Implementation Method 1

an open hot melt adhesive fleece with which the pad cover is equipped is heated during this process to bond it to the knitted body

Methodology Applied

Scientific EffectHot melt adhesive bonding: Melting

Implementation Method 2

capacitive heating for bonding

Methodology Applied

Scientific EffectCapacitive heating: Dielectric Heating

Implementation Method 3

maintaining high elasticity and vapor permeability

Methodology Applied

Scientific EffectVapor permeability: Permeation

Data Source

PatentEP4486276B1Method for fastening a truss pad to an elastic knitted body, method for producing a dressing, knitted body having a truss pad fastened thereto, and dressing

Publication Date: 2025.12.31 THUASNE DEUT GMBH

Figure 1
Figure 2a~2b
Figure 3a~3b

AI summary

The invention relates to a method for fastening a truss pad to an elastic knitted body. Here, a truss pad is placed on the knitted body and then a truss-pad cover, which is provided with a melded nonwoven, is placed on the truss pad and the edge of the truss-pad cover is pressed against the knitted body annularly around the contour of the truss pad. During this process, the melded nonwoven is heated in order to bond the truss-pad cover to the knitted body annularly around the contour of the truss pad. The invention also relates to: a method for producing a dressing having increased elasticity and vapour permeability in the truss-pad region, the truss pad of which is accordingly fastened to the knitted body; and to the knitted body having the truss pad fastened thereto; and the dressing.