Engineered Woven Fabric Pockets With Zoned Stretch Support
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Solution Overview
Problem
Existing garments with pocket bags require time-consuming cutting and sewing, leading to fabric waste and unattractive baggy pockets.
Innovation Solution
An engineered woven fabric with seamlessly integrated pockets, featuring a single-layer portion and a double-layer portion with varying stretchability zones, allowing for seamless construction and enhanced support around the pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pocket bags are constructed by cutting and sewing separate fabric panels, then pocket bags can be formed with structural support, but the process is time-consuming and increases fabric waste
Solution Approach 1:
The patent merges the pocket bag construction with the main garment fabric by integrating the pocket bag as an inherent part of the woven fabric structure. This is achieved by forming the pocket bag from the same continuous fabric panels that make up the garment, eliminating the need for separate cutting and sewing operations. The pocket bag and garment body are manufactured as a single integrated piece, thereby resolving the contradiction by improving manufacturing efficiency while eliminating time loss from multiple processing steps.
Solution Approach 2:
The fabric panels serve multiple functions simultaneously: they form both the main garment body and the pocket bag structure. The same fabric material and weaving process create both the outer garment and the integrated pocket, making the manufacturing process universal rather than requiring separate specialized operations for each component. This multi-functionality resolves the time-consuming nature of traditional multi-step construction.
2Ease of manufacture
If pocket bags are constructed by cutting and sewing separate fabric panels, then pocket bags can be formed, but extra fabric is needed and fabric waste increases
Solution Approach 1:
The pocket bag is merged with the garment fabric so that no separate fabric panels are required. The pocket bag is formed from the same continuous fabric that makes up the garment body, eliminating the need for additional fabric materials. This integration directly resolves the contradiction by improving fabric utilization efficiency while preventing fabric waste that would otherwise occur from cutting and discarding excess material.
Solution Approach 2:
The fabric structure itself provides the pocket bag functionality without requiring external or additional fabric resources. The weaving process creates the pocket bag as a self-contained feature within the garment fabric, making the fabric self-sufficient for both garment construction and pocket formation, thereby eliminating fabric waste.
3Shape
If pocket bags are constructed by cutting and sewing separate fabric panels, then pocket bags can be formed, but the resulting pockets appear baggy, hanging, and distracting
Solution Approach 1:
The pocket bag is merged with the garment fabric as a single integrated structure, eliminating the seams and joints where traditional separate-panel construction creates bulk and distortion. The continuous fabric structure allows the pocket to lie flat and smooth against the garment body, resolving the appearance issue while maintaining manufacturing simplicity through the integrated weaving process.
Solution Approach 2:
The fabric structure is locally optimized in the pocket bag region to provide the necessary shape and smooth appearance. The weaving pattern and tension are controlled specifically in the pocket area to prevent bagging and hanging, while the rest of the garment maintains its overall structure. This local quality control resolves the appearance contradiction without complicating the overall manufacturing process.
4Ease of manufacture
If fabric panels are made with uniform stretchability, then the fabric is easy to manufacture, but the pocket lacks support and resistance to sagging
Solution Approach 1:
The fabric is engineered with different stretchability characteristics in different regions: the pocket bag area has reduced stretchability to provide support and prevent sagging, while other areas of the garment maintain appropriate stretchability for comfort and fit. This local differentiation in fabric properties resolves the contradiction by providing pocket support strength without requiring complete redesign of the entire fabric construction process.
Solution Approach 2:
The stretchability parameter of the fabric is changed specifically in the pocket bag region through controlled variations in weaving tension, yarn selection, or pattern density. This parameter modification allows the pocket area to have lower stretchability for support, while the rest of the garment maintains its original stretchability characteristics, resolving the contradiction between manufacturing simplicity and pocket support strength.
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
Minimizes fabric waste and provides a smoother, more attractive appearance by integrating pockets seamlessly while maintaining support and resistance to sagging.
Implementation Method 1
a first stretching modulus zone (438) in a first portion (404) of the engineered woven fabric (400) with a first level of stretchability and a second stretching modulus zone (432) in a second portion (430) of the engineered woven fabric (400) with a second level of stretchability
Data Source
AI summary
Examples of an article of clothing including an engineered woven fabric are described. The article of clothing includes a single-layer woven portion and a double-layer woven portion seamlessly joined with the single-layer woven portion to form a pocket. The pocket includes closed side edges seamlessly joined with the single-layer woven portion and an opening. The single-layer woven portion is engineered with a first stretching modulus zone with a first level of stretchability and a second stretching modulus zone with a second level of stretchability, such that the first level of stretchability is greater than the second level of stretchability. The second stretching modulus zone is located around the closed edges of the pocket to provide support around the pocket.