Fabric Join Impermeabilization Using Cauterization and Hot Taping
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Solution Overview
Problem
The existing methods for creating impermeable joins in three-layer or two-layer fabrics are inefficient due to the capillary effect of liquids passing through the stitching zones, requiring complex and time-consuming preparatory operations like fleshing or shaving, which can damage the fabric and result in incomplete impermeabilization.
Innovation Solution
A machine that cauterizes the internal layer of the fabric along the joining line, followed by the application of an adhesive and impermeable tape, effectively sealing the join without prior treatment, using either compressed super-heated air or irradiation heating to modify the filament structure and prevent liquid penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stitching operation is performed to join panels, then the fabric can be assembled into garments, but liquid penetration occurs through capillary effect in the stitching zone
Solution Approach 1:
The patent applies preliminary action by performing fleshing or shaving operations before stitching to remove the third internal layer along the joining edges, exposing the second intermediate impermeable layer. This preparatory step ensures that when stitching occurs, the needle penetrates only the first external layer and second intermediate layer, preventing liquid penetration through the stitching zone while maintaining garment assembly capability
Solution Approach 2:
The patent applies local quality by creating a differentiated structure where the third internal layer is selectively removed only along the joining edges (local area) while preserving it in the panel bodies. This localized modification allows the stitching zone to have impermeable characteristics (exposed second layer) while the rest of the fabric maintains its original three-layer structure with comfort and insulation properties
2Reliability
If fleshing or shaving operation is performed to remove third layer, then impermeability is improved, but the operation is complex, slow, and can damage the second intermediate layer
Solution Approach 1:
The patent replaces complex mechanical fleshing/shaving machines with a simplified mechanical system consisting of a cutting device with blades that reciprocate to cut and remove the third layer. This substitution maintains the effectiveness of exposing the second intermediate layer while significantly reducing device complexity and operational difficulty, making the process easier to control and less prone to damaging the second layer
Solution Approach 2:
The patent applies parameter changes by controlling the cutting depth and blade reciprocation parameters to precisely remove only the third internal layer without penetrating the second intermediate layer. By adjusting these parameters, the process achieves effective fleshing while reducing complexity and minimizing the risk of damage to the impermeable second layer
3Reliability
If fleshing or shaving operation is performed, then impermeability is improved, but production time is increased due to complex preparation
Solution Approach 1:
The patent replaces slow and complex fleshing/shaving machines with a streamlined cutting device that uses reciprocating blades to efficiently remove the third layer. This mechanical substitution significantly reduces the time required for the preparatory operation while maintaining the quality of impermeability, thereby improving overall production speed without sacrificing reliability
4Reliability
If fleshing or shaving operation is performed, then impermeability is improved, but fabric thickness is increased and comfort is reduced
Solution Approach 1:
The patent applies preliminary action by removing the third internal layer along the joining edges before assembly, which reduces the overall thickness in the stitching zones. This preparatory fleshing operation ensures that when panels are joined, the combined thickness at the seams is minimized, maintaining comfort and wearability while achieving impermeability through the exposed second intermediate layer
Solution Approach 2:
The patent applies local quality by selectively removing the third layer only in the joining edge regions while preserving it in the panel bodies. This localized modification reduces thickness only where necessary for impermeability (at the seams) while maintaining the insulating and comfortable thick three-layer structure in the main fabric areas, thus balancing impermeability with comfort
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 simplifies the impermeabilization process to two steps, ensuring a reliable and quick impermeable join while maintaining the fabric's comfort and thickness, without the need for mechanical preparation, thus enhancing the impermeability and reducing operational complexity.
Implementation Method 1
heating means suitable to effect a cauterization of the material of the internal layer and positionable directly upstream of the second movement means in the direction of feed
Implementation Method 2
the heating means comprise a blower device able to blow compressed and super-heated air at least toward the joining line and on the sides adjacent thereto, in order to determine the cauterization of the internal layer
Implementation Method 3
the heating means comprise an irradiation heating device, able to be taken into close proximity, but not in contact, with the internal layer along the joining line, and to heat the internal layer by irradiation, obtaining the cauterization thereof
Implementation Method 4
the effect of the capillarity of the liquids that penetrate into the fabrics, in particular passing from the first external layer to the third internal layer in correspondence with the stitching zone
Data Source
Figure 1
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AI summary
A machine (10) for making an impermeable join between two panels (12, 14) made of three-layer or two-layer textile material (11) comprising at least an internal layer (20), already joined along a joining line (15) by means of a stitching operation, simple or complex, or by ultrasound joining or other, comprises first movement means (24) able to move the textile material (11) in a direction of feed (F) and impermeabilization means able to achieve the impermeabilization along said joining line (15) and comprising second movement means (30) able to move an impermeable tape (32) for hot taping with adhesive, in order to determine the hot application and welding on said internal layer (20) along said joining line (15). The impermeabilization means also comprise heating means (38, 138) suitable to effect a cauterization of the material of said internal layer (20) and positionable directly upstream of said second movement means (30) in said direction of feed (F), so that the hot taping can be effected immediately after the cauterization.