Flush Apparel Patch Repair for Damaged ePTFE Fabric
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Solution Overview
Problem
Current methods for repairing damaged outdoor apparel, particularly those made from expanded polytetrafluoroethylene (ePTFE) such as GORE-TEX fabric, are costly and yield less than desirable results.
Innovation Solution
A method for repairing apparel by removing damaged portions and replacing them with a patch that includes a layer filling the aperture, which can be made of thermoplastic or thermoset materials, and optionally backed by a substrate, ensuring the repaired area is flush or textured to match the original fabric, and can include embossing for customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If current repair methods are used for damaged ePTFE apparel, then the repair cost is reduced, but the repair quality and durability are insufficient
Solution Approach 1:
The patent changes the physical state parameter of the thermoplastic layer from solid to molten by heating, enabling it to flow and fill the aperture completely. This parameter change allows the repair material to conform precisely to the damaged area while maintaining bonding integrity, resolving the contradiction between cost-effective repair and high-quality results
Solution Approach 2:
The patent uses a composite structure consisting of a substrate and a thermoplastic layer. The substrate provides structural support while the thermoplastic layer provides bonding and sealing capabilities. This composite approach enables cost-effective repair using simpler materials while achieving reliable repair quality through the synergistic combination of materials with complementary properties
2Reliability
If a patch is applied to repair large damaged areas, then the repair effectiveness is improved, but the appearance and texture matching deteriorate
Solution Approach 1:
The patent applies local quality by making the patch properties location-dependent: the thermoplastic layer is positioned specifically within the aperture to provide sealing and bonding, while the substrate extends beyond to provide structural support. This localized functional differentiation allows the patch to effectively repair large damaged areas while maintaining appearance matching through precise material placement and property distribution
Solution Approach 2:
The patent changes the temperature parameter of the thermoplastic layer to enable it to flow and conform to the surrounding fabric texture and appearance. By heating the layer to its melting point and then cooling it, the material transitions from a flowable state that matches the fabric texture to a solid state that provides durable repair, resolving the contradiction between repair effectiveness and appearance matching
3Device complexity
If standard patching methods are used, then the repair process is simple, but the water-resistant and breathable properties are compromised
Solution Approach 1:
The patent applies homogeneity by using a thermoplastic layer that, when melted and cooled, becomes indistinguishable from the surrounding ePTFE fabric in terms of water-resistant and breathable properties. The thermoplastic material is selected to have comparable functional characteristics to the original fabric, creating a homogeneous repair that maintains the fabric's essential properties without requiring complex multi-step processes
Solution Approach 2:
The patent changes the physical state of the thermoplastic layer through temperature control during the repair process. By heating the layer to melt it and then cooling it to solidify, the process creates a bond that restores the water-resistant and breathable properties of the fabric. This simple parameter change approach maintains fabric properties without requiring complex repair procedures
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
The method allows for fast, cost-effective repair of larger damaged areas, reducing waste and enabling customization while maintaining the fabric's water-resistant and breathable properties.
Implementation Method 1
the layer is in a molten state so as to flow into the aperture
Implementation Method 2
the cooler is lowered onto the patch to cool the layer; setting the layer
Data Source
AI summary
An apparel may include a panel having an apparel panel with an aperture extending through the panel from an interior face to an exterior face of the apparel panel. A patch extends opposite the apparel panel and across the aperture on the interior face of the apparel panel. The patch may include a layer joined to portions of the apparel panel about the aperture and filling the aperture so as to be flush with the exterior face of the apparel panel.