Encased Underwire Casing Using Elastomeric Yarns
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Solution Overview
Problem
Conventional tubular fabrics for underwires in garments, such as brassieres, often suffer from underwire protrusion issues due to the stiffness and reduced comfort caused by fusible yarns used as penetration barriers, leading to product failure and increased manufacturing costs.
Innovation Solution
The development of an encased wire using a casing made from a combination of nylon and spandex, with varying woven densities to provide a flexible and comfortable fit while resisting underwire penetration, utilizing modified sewing machines to form the casing without relying on fusible yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fusible yarn is used as penetration barrier in tubular fabric, then underwire penetration resistance is improved, but fabric softness and comfort are reduced
Solution Approach 1:
The patent changes the physical state of the yarn from fusible (thermoplastic) to non-fusible (elastomeric), fundamentally altering the mechanism by which penetration resistance is achieved. Instead of melting to block wires, the elastomeric yarn maintains its elastic properties to provide resistance while preserving softness and comfort.
Solution Approach 2:
The patent applies different yarn types in different locations within the tubular fabric structure. Elastomeric yarns are specifically positioned to provide penetration resistance while maintaining overall fabric softness, creating localized functional differentiation without compromising global comfort properties.
2Reliability
If fusible yarn is used as penetration barrier, then underwire penetration resistance is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the fusible component from the yarn system and replaces it with elastomeric materials. This eliminates the need for thermal processing equipment and fusible yarn manufacturing steps, simplifying both the material supply chain and the manufacturing process while maintaining penetration resistance through elastic mechanics rather than thermal fusion.
3Reliability
If fusible yarn is melted to form penetration barrier, then underwire penetration resistance is improved, but fabric stiffness increases and comfort decreases
Solution Approach 1:
The patent fundamentally changes the mechanical parameters of the yarn by replacing thermoplastic fusible materials with elastomeric materials that maintain flexibility. The elastomeric yarns undergo elastic deformation rather than plastic fusion, preserving fabric softness and preventing stiffness while still providing effective penetration resistance through their elastic recovery properties.
4Reliability
If fusible yarn is used in tubular fabric, then penetration barrier function is improved, but production efficiency decreases
Solution Approach 1:
The patent removes the fusible yarn component and its associated thermal processing requirements from the manufacturing system. This eliminates heating equipment, temperature control systems, and multi-step fusion processes, replacing them with a simpler elastomeric yarn insertion process that can be integrated into existing knitting or weaving machines without additional thermal processing infrastructure.
Data Source
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AI summary
An encased wire for a garment includes a wire with first and second ends and a casing surrounding the wire. The casing includes a first fabric ribbon woven from a polyamide that resists penetration by at least one of the ends of the wire. The casing has a first edge, a second edge, and a first, stitched seam disposed adjacent to the first edge to close the casing, thereby containing the wire. The casing may be a single layer construction or a multi-layer construction. Selected regions of the casing resist penetration by the wire. Other selected regions provide increased comfort to the wearer. A sewing machine and a method of manufacture of the casing also are provided.