Foamed Adhesive Core Material Placement for Bra Cup Garments
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Solution Overview
Problem
Existing methods for manufacturing core-material-containing garments, such as brassieres, require multiple steps and face challenges in positioning and displacement of core materials during bonding, leading to potential needle breakage and inefficiencies.
Innovation Solution
A method involving the application of reactive hot-melt adhesive, which is applied using a movable application device in two axial directions, allowing direct molding of the core material without a casing, and utilizing nitrogen gas for foaming to adjust softness and rigidity, facilitating precise positioning and reducing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a casing is formed and the core material is inserted into the casing, then the core material can be fixed to the garment, but the number of manufacturing steps increases and needle breakage risk increases due to sewing requirements
Solution Approach 1:
The patent removes the intermediate casing component entirely and extracts the core material fixation function directly onto the garment fabric. The adhesive application device applies adhesive directly to the garment surface, eliminating the need to form a casing, insert the core material, and sew it in place. This reduces manufacturing steps from multiple operations (casing formation, insertion, sewing) to a single adhesive application and bonding operation.
Solution Approach 2:
The patent merges the core material fixation function with the garment fabric itself by applying adhesive directly to the garment surface. Instead of fixing the core material to a separate casing that is then attached to the garment, the core material is bonded directly to the garment cups through adhesive application, combining multiple functions into a single integrated structure.
2Productivity
If the core material is directly bonded to the garment with pressure-sensitive adhesive, then the number of steps is reduced, but positioning accuracy deteriorates as the core material must be cut in advance and positioning is difficult
Solution Approach 1:
The adhesive application device performs preliminary positioning actions by applying adhesive in a controlled pattern to predetermined locations on the garment cups before the core material is placed. The adhesive is applied in advance at exact positions, creating reference points that guide subsequent core material placement and ensure accurate positioning without requiring pre-cutting of the core material.
Solution Approach 2:
The patent replaces manual positioning and mechanical cutting operations with an automated adhesive application system. The adhesive application device uses programmed motion control to apply adhesive at precise coordinates on the garment, substituting manual measurement and positioning operations with automated digital positioning, thereby achieving high positioning accuracy while maintaining reduced manufacturing steps.
3Ease of manufacture
If the core material and mold are positioned in advance, then the bonding process can proceed, but displacement occurs during bonding reducing positioning accuracy
Solution Approach 1:
The adhesive acts as an intermediary substance between the garment and the core material, creating a bonding interface that prevents displacement during the bonding process. The adhesive application device applies adhesive that maintains its position on the garment surface, serving as a stable intermediary layer that holds the core material in place once contacted, preventing the displacement problems that occur with direct mechanical bonding methods.
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 approach reduces the number of manufacturing steps and enhances positioning accuracy, resulting in a more efficient and automated process for producing core-material-containing garments with improved fit and comfort.
Implementation Method 1
the reactive hot-melt adhesive is preferably mixed with nitrogen gas and foamed
Data Source
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AI summary
A method for manufacturing a core-material-containing garment, the method includes: a feeding step of feeding fabric (2) in a wound state onto a conveyor table (1) without relaxing or substantially relaxing the fabric (2); a core material application step of applying a reactive hot-melt adhesive to the fabric (2) on the conveyor table (1) to form a core material (12); an adhesive application step of applying a bonding hot-melt adhesive (13) configured to bond the fabric (2); and a drying step of drying the applied bonding hot-melt adhesive (13), and in the core material application step, the reactive hot-melt adhesive is mixed with nitrogen gas and foamed, and the reactive hot-melt adhesive is applied using an application device provided with a resin discharge unit that is movable in at least two axial directions of vertical and horizontal directions.