Fabric With Flow Restricting Core For Uniform Foam Thickness

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Solution Overview

Problem

Controlling the depth of penetration of foaming chemicals or coating materials into fabrics is challenging due to their non-uniform expansion and flow, leading to irregularities such as uneven thickness and appearance.

Innovation Solution

A fabric construction method involving a barrier layer and yarn stitching, where the barrier layer is heated to control the penetration depth of a foam core, and a composite barrier layer with distinct melting points for adhesive and intermediate materials to manage stitch hole filling and foam expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If foaming chemicals or coating materials are applied to fabric, then the fabric gains insulation or protective properties, but the materials expand and flow non-uniformly causing irregular thickness and appearance

Engineering Contradiction:

Improveinsulation propertyVSAvoidthickness uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A barrier layer is applied to the fabric before the foaming chemical is applied. This barrier layer is positioned in advance to control where the foam will expand, preventing non-uniform expansion and ensuring consistent thickness and appearance while maintaining insulation properties.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The barrier layer acts as an intermediary between the fabric and the foaming chemical. It mediates the interaction by controlling the flow and expansion of the foam, ensuring uniform distribution and preventing irregularities in thickness and appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If a barrier layer is added to control foam penetration, then thickness uniformity is improved, but the fabric structure becomes more complex

Engineering Contradiction:

Improvethickness uniformityVSAvoidfabric structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The barrier layer is implemented as a thin film or flexible layer that can be easily integrated into the fabric structure. This thin film approach provides effective foam control while minimizing added complexity and maintaining fabric flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

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 precise control of foam core penetration, ensuring uniform thickness and appearance, while maintaining breathability and water resistance, and can be applied to various articles like garments and beverage coolers.

Implementation Method 1

the barrier layer is heated to control the penetration depth of a foam core

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a foam core formed from a foaming agent applied over the barrier layer

Methodology Applied

Scientific EffectFoam expansion: Foam

Data Source

PatentUS20240367410A1Fabric with Flow Restricting Core

Publication Date: 2024.11.07 SWNR DEV

AI summary

A stitched fabric including a barrier layer; a yarn stitched through and forming stitch holes in the barrier layer, and a foam core formed over the barrier layer. A melted portion of the barrier layer fills at least a portion of the stitch holes. The foam core is prevented from progressing further into the stitched fabric by the barrier layer. As such, the barrier layer is configured to control a depth to which the foam core penetrates into the stitched fabric. The foam core may be formed over at least a portion of the yarn. A second foam core may be formed on a side of the barrier layer opposite the foam core.