EMS Training Garment Electrode Fixation via Embroidery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing training garments for Electrical Muscle Stimulation (EMS) face challenges in accurate electrode alignment and lengthy manufacturing processes, with existing solutions being labor-intensive and compromising comfort and stability of electrode fixation.
Innovation Solution
A method involving fabric tailoring, embroidery-based fixation of close-fitting electrodes and elastic electric leads, and a connector system for a portable EMS generator, utilizing silver-plated cloth with an elastic layer and thin film for uniform conductivity and comfort, and low-energy consumption electric leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are fixed onto the garment by sewing, then the fixation stability is improved, but the manufacturing process becomes highly labor-consuming and time-intensive
Solution Approach 1:
The patent replaces the mechanical sewing process with an embroidery-based fixation system. The embroidery machine automatically stitches electrodes onto the garment using conductive thread, eliminating manual sewing operations. This substitution maintains fixation stability through dense stitching patterns while dramatically improving manufacturing efficiency through automation.
Solution Approach 2:
The embroidery machine performs multiple functions in one process: it fixes electrodes onto the garment, creates electrical connections between electrodes, and integrates conductive leads simultaneously. The system serves itself by using the same embroidery mechanism for both aesthetic and electrical connection purposes, reducing the need for separate manufacturing steps.
2Ease of manufacture
If electrodes are adhered onto the garment by glue or hook and loop fasteners, then the manufacturing process is simplified, but the comfort and stability of electrode fixation are compromised
Solution Approach 1:
The patent uses composite electrode structures that combine conductive materials with fabric substrates. The electrodes are made from conductive thread embedded in fabric bases, creating a composite material that is both comfortable against the skin and electrically conductive. This composite approach maintains stability without requiring adhesives or fasteners.
3Stability of the object's composition
If conventional sewing machines are used to operate on three-dimensional garments, then the garment structure is maintained, but the sewing operation cannot be performed automatically and becomes highly labor-consuming
Solution Approach 1:
The patent replaces conventional sewing machines with embroidery machines that are specifically designed for automated operation. The embroidery machine uses a flatbed mechanism that can accommodate the three-dimensional garment structure while performing automated stitching operations. This substitution enables automation without compromising garment structure integrity.
4Adaptability or versatility
If multiple separate steps are used to fix electrodes and electric leads, then each component can be optimized independently, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent merges the fixation of electrodes and electric leads into a single embroidery process. The embroidery machine simultaneously stitches both components onto the garment in one operation, eliminating the need for separate fixation steps. This merging reduces manufacturing complexity and time while maintaining the ability to optimize each component's design independently.
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 ensures accurate electrode alignment, reduces manufacturing time, enhances comfort and stability, and maintains conductivity and durability even after multiple washes, while ensuring efficient energy use and easy garment use.
Implementation Method 1
The surface and deep muscles and the fast-twitch and slow-twitch muscles can be all simultaneously 'mobilized' to participate in activities by electrical signals. The current is distributed uniformly without any local peak discharge which stimulates the human body
Implementation Method 2
The electrodes can be fully fitted to the outline of the human body. The electric wires connecting the current generator with the electrodes are highly elastic and thus make the user feel comfortable, so that the free movement of the human body is ensured
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention discloses a method for manufacturing training garments using EMS, which comprises the following steps: 1) preparing a semi-finished training garment, comprising: (A) fabric tailoring, (B) fixing close-fitting electrodes (1), (C) fixing elastic electric leads (2), (D) sewing waist darts, (E) providing an electric generator connector; 2) manufacturing a finished training garment, comprising: folding left and right portions of the cloth piece (3) obtained in step (E), partially sewing the folded cloth piece (3) at a junction of the inner side of the legs and a junction of the back, providing a slide fastener (6) in the remaining portion of the junction of the back so as to form a garment body (7), sewing the lower sleeve pieces (4) to positions of the garment body (7) corresponding to the arms to form sleeves (71), and connecting the external EMS electric generator to the electric connector (5) to form a training garment using EMS.